Apparatus, systems and methods for modular construction

ABSTRACT

Methods of modular building construction are provided. One method includes (a) providing a first volumetric construction module comprising a frame, the frame including a first segment; (b) defining a volume of a composite segment and integrating the first segment with the volume; and (c) filling the volume with a curable material to cast the composite segment. Related methods, components, buildings incorporating such components, and methods of manufacture of components are also provided.

RELATED APPLICATION

This application claims priority to, and incorporates by reference inits entirety, U.S. provisional application No. 61/570,656 filed 14 Dec.2011.

TECHNICAL FIELD

The invention relates to modular construction of buildings. Embodimentsof the invention provide volumetric construction modules, methods forassembling such modules into buildings, and buildings and structuralcomponents of buildings constructed from such modules.

BACKGROUND

Modular building construction has many advantages over conventionalbuilding construction. For example, prefabricated construction sectionscan be manufactured away from construction sites at centralizedfactories, which may permit more productive use of time, labour,material and equipment. Modular construction also presents fewerlogistical challenges than conventional construction by marshalling andassembling materials, devices and equipment off site in factoryconditions and thereby reducing the variety of materials and componentsrequired during construction and by permitting efficient division andscheduling of on-site construction tasks. Modular construction may alsobe performed with less extensive site preparation, and can streamlinethe process of obtaining engineering approval. These and otheradvantages of modular construction may be especially pronounced in theconstruction of multi-story buildings. For instance, modularconstruction may allow for a smaller construction site footprint, sincearranging just-in-time delivery of and storage for fewer and lessvarious prefabricated construction sections is simpler than for morediverse materials and components used in conventional construction.

Additional economic advantages may be realized in modular constructionby using prefabricated volumetric construction modules. For example,prefabricated volumetric construction modules may allow pre-installation(e.g., before delivery to the construction site or at the constructionsite before placement of the module in the building) of utilityconnections (e.g., plumbing, electricity wiring, HVAC, fire protection,etc.), interior finishing (e.g., kitchen fixtures, bathroom fixtures,cabinetry, drywall, curtain walls, etc.), and fenestration hardware(e.g., doors, windows, casings therefore, etc.). Prefabricatedvolumetric construction modules may also be configured to accord withthe dimensions of intermodal shipping containers, thereby simplifyingand economizing transportation, handling and assembly of the modules.

Building codes in much of the world require buildings to meet minimumstructural strength criteria. In some areas of the world, building codesrequire buildings to meet structural strength and stiffness criteriasufficient to withstand the loads that occur during seismic events. Itis a challenge to construct multi-story buildings that have adequatestructural strength from prefabricated structural sections withoutincurring costs that extinguish the economic advantages of modularconstruction. The challenge of constructing multi-story buildings isespecially daunting when using volumetric construction modules, due tothe lack of continuity of the volumetric construction modules structuralmembers.

Most modern residential high rise buildings are built with concretereinforced with rebar. In these buildings it is conventional to providereinforced concrete diaphragms that span shear walls and/or buildingframes. The concrete diaphragms transmit horizontal forces to the shearwalls and/or building frames. Though it is possible to constructconventional buildings with rebar reinforced concrete walls and slabdiaphragms around volumetric construction modules employing the modulesas formwork, (such as is described in Published PCT Application no. WO2009/061702), in general this is not cost efficient.

Another aspect of this challenge is the problem of providing verticaland lateral load bearing members that are sufficiently strong to supportbuildings having at least several stories. Currently, it is conventionalto provide reinforced concrete columns by encasing steel re-bar inconcrete. This typically involves casting concrete in and around re-barcages, which requires tying steel re-bar and assembling concreteformwork around the rebar on-site. For multi-story buildings, thisrequires tying steel-rebar, and placing and removing concrete forms atprogressively higher floors. The connections of beams to columns areparticularly challenging for rebar installation due to congestion ofrebar required to counteract the forces concentrated at these locations.Setting, stripping, cleaning, rigging and resetting formwork is alsotime consuming and labour intensive particularly for concrete slabsoffit forms.

There is accordingly need for volumetric construction modules, buildingsystems and construction methods that facilitate construction ofstructurally strong multi-story buildings from prefabricated volumetricconstruction modules.

References in the general field of the technology include the following:

-   CA 2,542,184 □BUILDING MODULES-   U.S. Pat. No. 3,331,170 □PREASSEMBLED SUBENCLOSURES ASSEMBLED TO    FORM BUILDING CONSTRUCTION-   U.S. Pat. No. 3,514,910 □MODULAR BUILDING CONSTRUCTION-   U.S. Pat. No. 4,599,829 □MODULAR CONTAINER BUILDING SYSTEM-   U.S. Pat. No. 5,584,151 □EARTHQUAKE, WIND RESISTANT AND FIRE    RESISTANT PRE-FABRICATED BUILDING PANELS AND STRUCTURES FORMED    THEREFROM-   U.S. Pat. No. 7,827,738 □SYSTEM FOR MODULAR BUILDING CONSTRUCTION-   US 2003/0188507 □METHOD FOR CONSTRUCTING MODULAR SHELTERS USING    RECYCLED LAND/SEA SHIPPING CONTAINERS-   US 2005/0223651 □BARRIER-PROTECTED CONTAINER-   US 2006/0185264 □PREFABRICATED BUILDING METHOD-   US 2008/0307729 □STRUCTURAL PANELS-   US 2007/0084135 □CONSTRUCTION SYSTEM FOR STEEL-FRAME BUIDLINGS-   US 2011/0036018 □MOVABLE BUILDING-   WO 2009/061702 □MODULAR BUILDING CONSTRUCTION UNIT, SYSTEM, AND    METHOD-   WO 2009/132387 □FIRE RATED, MULTI-STOREY, MULTI-DWELLING STRUCTURE    AND METHOD TO CONSTRUCT SAME-   WO 2011/15836 □MODULAR BUILDING AND FOUNDATION SYSTEM THEREFOR AND    METHODS FOR THEIR CONSTRUCTION-   DE 3716795 □FORMWORK FOR AN UNDERGROUND BOMB SHELTER-   FR 2710087 □CONSTRUCTION COMPONENTS AND METHODS FOR MAKING THEM-   GB 8323946 □PORTABLE BUILDING-   GB 2146053 □PORTABLE BUILDING-   EP 1123449 □VOLUMETRIC MODULAR BUILDING SYSTE

The foregoing examples of the related art and limitations relatedthereto are intended to be illustrative and not exclusive. Otherlimitations of the related art will become apparent to those of skill inthe art upon a reading of the specification and a study of the drawings.

SUMMARY

The following embodiments and aspects thereof are described andillustrated in conjunction with systems, tools and methods which aremeant to be exemplary and illustrative, not limiting in scope. Invarious embodiments, one or more of the above-described problems havebeen reduced or eliminated, while other embodiments are directed toother improvements.

An aspect of the invention provides a method of modular buildingconstruction comprising (a) providing a first volumetric constructionmodule comprising a frame, the frame comprising a first segment; (b)defining a volume of a composite segment and integrating the firstsegment with the volume; and (c) filling the volume with a curablematerial to cast the composite segment. The method may include, prior tostep (b), step (a)(i) comprising providing a structure adjacent thefirst volumetric construction module, the adjacent structure comprisinga second segment, and wherein step (b) comprises integrating the firstsegment and the second segment with the volume. In step (b) the volumemay contain at least a portion of the first and second segments. Step(b) may comprise defining a boundary of the volume with temporaryformwork. Step (b) may comprise defining at least a portion of theboundary of the volume with the first and second segments. The adjacentstructure may comprise a second volumetric construction modulecomprising a frame including the second segment. The curable materialmay comprise a high strength curable material, such as carbon fibrereinforced polymer or high strength concrete.

The method may include, prior to step (b), step (a)(ii) comprisingaugmenting structural capacity of the composite segment. Step (a)(ii)may comprise coupling the first segment and/or the second segment to aplurality of shear connectors extending into the volume. Step (a)(ii)may further comprise coupling a column reinforcement member to theplurality of shear connectors. Step (a)(ii) may comprise providing acolumn closure member opposite to the first segment and/or the secondsegment, the column closure member defining a portion of the boundary ofthe volume. The column closure member may be coupled to a plurality ofshear connectors extending into the volume. Step (a)(ii) may compriseproviding a plurality of first and second reinforcement elements, thefirst and second reinforcement elements extending in transverse planeswith respect to each other. The first reinforcement elements maycomprise rebar rods and the second reinforcement elements comprise rebarstirrups. Step (a)(ii) may further comprise providing a plurality offirst and second reinforcement elements, wherein the secondreinforcement elements engage the shear connectors. The firstreinforcement elements may comprise rebar rods and the secondreinforcement elements comprise rebar stirrups. Step (a)(ii) maycomprise coupling the first segment and the second segment by wrappingthe segments with fibre reinforced polymer wrap.

Each of the first and second volumetric construction modules may have anopening defined in its side that faces the other module, wherein thevolume may comprise a space between the modules adjacent the openings.The volume may comprise a space between adjacent corners of the frame ofthe at least one of the first and second volumetric constructionmodules. The volume may comprise a space adjacent an edge of the frameof at least one of the first and second volumetric construction modules.The first and second volumetric construction modules may be provided inlaterally adjacent relation. The first and second volumetricconstruction modules in laterally adjacent relation may compriseproviding the modules such that a side of one module is adjacent a sideof the other module, or such that an end of one module is adjacent aside of the other module, or such that an end of one module is adjacentan end of the other module. The frame of each of the first and secondvolumetric construction module may comprise a plurality of verticalposts, wherein the volume comprises a space between opposed posts of themodules. The frame of each of the first and second volumetricconstruction module may comprise a horizontal rail, wherein the volumecomprises a space between opposed rails of the modules. Each of thefirst and second volumetric construction module may comprise a panelsection fastened to the frame, wherein the volume comprises a spacebetween opposed panel sections of the modules.

Adjacent upper portions of the frames may be bridged with a structuralmember to provide a bottom boundary of a slab volume. The structuralmember may comprise one or more upwardly extending shear connectors. Theshear connectors may extend past the top of the frames. A plurality ofrebar rods and rebar stirrups may be provided in the slab volume. Thestructural member may comprise a hot or cold rolled steel section, suchas a plate, I beam or truss. A boundary of the slab volume may bepartially defined by a spacer installed above the first volumetricconstruction module and/or the second volumetric construction module.The top corners of the frame of each of the first and second volumetricconstruction modules may comprise corner fittings having upper orifices,wherein the spacer comprises at least one downward projection, andwherein installing the at least one spacer comprises mating the at leastone downward projection with one of the upper orifices. A curablematerial may be introduced to the slab volume. An upper volumetricconstruction module may be provided above each of the first and secondvolumetric construction modules, each of the upper volumetricconstruction modules comprising a frame. At least bottom corners of theframe of each upper module may comprise corner fittings having lowerorifices, wherein the spacer comprises at least one upward projection,and wherein providing the upper volumetric modules above the volumetricconstruction modules comprises mating the at least one upward projectionwith one of the lower orifices.

Each of the frames of the first and second volumetric constructionmodules may comprise a rectangular parallelpiped frame. The rectangularparallelpiped frame may comprise at least a part of a frame of anintermodal shipping container. The curable material may compriseconcrete.

Another aspect of the invention provides a method of modular buildingconstruction comprising: (a) providing first and second volumetricconstruction modules in lateral relation, each module comprising aframe, the frame comprising a first segment; (b) providing a panelexpansion member spanning opposing top rails of the frames and a floorframe between opposing bottom rails of the frame, the space between thepanel expansion member and the floor frame defining an expansion space,wherein at least one of the panel expansion member and the floor framecomprise a second segment; (c) defining a volume of a composite segment,the volume integrating the first segment and the second segment; and (d)filling the volume with a curable material to cast the compositesegment. In step (c) the volume may contain at least a portion of thefirst and second segments. Step (c) may comprise defining a boundary ofthe volume with temporary formwork. Step (c) may comprise defining atleast a portion of the boundary of the volume with the first and secondsegments. The method may include, prior to step (d), a step (c)(i)comprising augmenting the structural capacity of the composite segment.Step (c)(i) may comprise coupling the first segment and/or the secondsegment to a plurality of shear connectors extending into the volume.Step (c)(i) may comprise providing a plurality of first and secondreinforcement elements, the first and second reinforcement elementsextending in transverse planes with respect to each other. The firstreinforcement elements may comprise rebar rods and the secondreinforcement elements comprise rebar stirrups.

Each volumetric construction module may have an opening defined in itsside that faces the expansion space, and wherein the volumes comprises aspace between the modules and the expansion space adjacent the opening.The volume may comprise a space between adjacent corners of the frame ofthe at least one of the first and second volumetric constructionmodules. The volume may comprise a space adjacent an edge of the frameof at least one of the first and second volumetric construction modules.A side of the first volumetric construction module may be aligned withthe side of the second volumetric construction module, with theexpansion space located therebetween. A side of the first volumetricconstruction module may be aligned with an end of the second volumetricconstruction module, with the expansion space located therebetween. Anend of the first volumetric construction module may be aligned with anend of the second volumetric construction module, with the expansionspace located therebetween. The panel expansion member may partiallydefine a bottom boundary of a slab volume above the modules and theexpansion space. The panel expansion member may comprise a structuralmember at two side regions of the panel expansion member whereinspanning opposing top rails comprises resting at least a portion of thestructural member on the top rails. The structural member may comprise ahot or cold rolled steel section, such as a plate, I beam or truss. Thestructural member may be provided with upwardly projecting shearconnectors. Each of the frames of the first and second volumetricconstruction modules may comprise a rectangular parallelpiped frame. Therectangular parallelpiped frame may comprise at least a part of a frameof an intermodal shipping container. The panel expansion member maycomprise at least a part of a panel of an intermodal shipping container.The floor frame may comprise at least a part of a floor frame of anintermodal shipping container. The curable material may compriseconcrete.

Another aspect of the invention provides a method of modular buildingconstruction comprising: (a) providing a first volumetric constructionmodule comprising a frame, the frame comprising a first segment; (b)providing a partially constructed building comprising a frame comprisinga second segment; (c) defining a volume of a composite segment, thevolume integrating the first segment and the second segment; and (d)filling the volume with a curable material to cast the compositesegment. In step (c) the volume may contain at least a portion of thefirst and second segments. Step (c) may comprise defining a boundary ofthe volume with temporary formwork. Step (c) may comprise defining atleast a portion of the boundary of the volume with the first and secondsegments. Prior to step (d), a step (c)(i) may comprise augmenting thestructural capacity of the composite segment. Step (c)(i) may comprisecoupling the first segment and/or the second segment to a plurality ofshear connectors extending into the volume. Step (c)(i) may furthercomprise providing a plurality of first and second reinforcementelements, the first and second reinforcement elements extending intransverse planes with respect to each other. The first reinforcementelements may comprise rebar rods and the second reinforcement elementsmay comprise rebar stirrups.

Another aspect of the invention provides a modular building diaphragmcomprising: roof panels of first and second volumetric constructionmodules in laterally adjacent relation; floor frames of third and fourthvolumetric construction modules in laterally adjacent relation, thethird and fourth modules above the first and second modules,respectively; a beam soffit member connected between upper portions ofthe first and second modules and having one or more shear connectorsextending upwardly between the third and fourth modules; and acontinuous body of concrete in contact with at least a portion of eachof the roof panels of the first and second modules, the laterallyadjacent portions of the third and fourth modules, and the beam soffitmember, the concrete bonded in composite action with the one or moreshear connectors of the beam soffit member.

Another aspect of the invention provides a modular building diaphragmcomprising: roof panels of first and second volumetric constructionmodules in laterally adjacent relation; floor frames of third and fourthvolumetric construction modules in laterally adjacent relation, thethird and fourth modules above the first and second modules and,respectively, bottom rails of the third and fourth modules rigidlyconnected by at least one shear connector; a structural member connectedbetween upper portions of the first and second modules; and at least onefirst reinforcing element extending in a direction parallel to a longaxis of the bottom rails; a plurality of second reinforcing elementsoriented in a plane transverse to the long axis of the bottom rails,each of the second reinforcing elements coupling the at least one shearconnector to the at least one first reinforcing element; and acontinuous body of concrete in contact with at least a portion of eachof the roof panels of the first and second modules, the laterallyadjacent portions of the third and fourth modules, the at least onefirst reinforcing element, the plurality of second reinforcing elements,and the structural member, the concrete bonded in composite action withthe one or more shear connectors of the beam soffit member.

Another aspect of the invention provides a column in a modular building,the column comprising: a first panel section of a first volumetricconstruction module; a second panel section of a second volumetricconstruction module, the second panel section parallel to and spacedapart from the first panel section; at least one shear connectorextending into a volume between the first panel section and the secondpanel section and attached to at least one of the first panel sectionand the second panel section; at least one column closure member closinglateral sides of the volume between the first panel section and thesecond panel section; and concrete in the volume bonded in compositeaction with the at least one shear connector. The first module may havean opening defined in part by an inward edge of the first panel section,wherein the second module has an opening defined in part by an inwardedge of the second panel section, and wherein the at least one columnclosure member borders the openings in the first and second modules. Atleast one shear connector may be attached to the at least more columnclosure member, wherein the concrete is bonded in composite action withthe at least one shear connector attached to the at least one columnclosure member.

Another aspect of the invention provides a column in a modular building,the column comprising: a first corner post section of a first volumetricconstruction module; a first vertically extending reinforcement member;a first plurality of shear connectors rigidly connecting the firstcorner post section to the first vertically extending reinforcementmember; a volume defined by temporary formwork, the volume surroundingand including the first corner post section, the first verticallyextending reinforcement member, and the first plurality of shearconnectors; and concrete in the volume encasing and bonding in compositeaction the first corner post section, the first vertically extendingreinforcement member, and the first plurality of shear connectors. Thecolumn may further comprise a second corner post section of a secondvolumetric construction module adjacent the first corner post section; asecond vertically extending reinforcement member; a second plurality ofshear connectors rigidly connecting the second corner post section tothe second vertically extending reinforcement member; wherein the volumeadditionally surrounds and includes the second corner post section, thesecond vertically extending reinforcement member, and the secondplurality of shear connectors; and wherein the concrete in the volumeadditionally encases and bonds in composite action the second cornerpost section, the second vertically extending reinforcement member, andthe second plurality of shear connectors.

Another aspect of the invention provides a column in a modular building,the column comprising: a first corner post section of a first volumetricconstruction module; a second corner post section of a second volumetricconstruction module adjacent the first corner post section; a firstplurality of shear connectors rigidly connecting the first corner postsection to the second corner post section; a volume defined by temporaryformwork, the volume surrounding and including the first corner postsection, the second corner post section, and the first plurality ofshear connectors; and concrete in the volume encasing and bonding incomposite action the first corner post section, the second corner postsection, and the first plurality of shear connectors. The column mayfurther comprise a third corner post section of a third volumetricconstruction module adjacent the first or second corner post section; afourth corner post section of a forth volumetric construction moduleadjacent the third corner post section; a second plurality of shearconnectors rigidly connecting the third corner post section to thefourth corner post section; wherein the volume additionally surroundsand includes the third corner post section, the fourth corner postsection, and the second plurality of shear connectors; and wherein theconcrete in the volume additionally encases and bonds in compositeaction the third corner post section, the fourth corner post section,and the second plurality of shear connectors.

Another aspect of the invention provides a column in a modular building,the column comprising: a first corner post section of a first volumetricconstruction module; at least one first reinforcing element extending ina direction parallel to a long axis of the first corner post section; atplurality of second reinforcing elements oriented in a plane transverseto the long axis of the first corner post section, each of the secondreinforcing elements surrounding both the first corner post section andthe at least one first reinforcing element; and a volume defined bytemporary formwork, the volume surrounding and including the firstcorner post section, the at least one first reinforcing element and theplurality of second reinforcing elements; and concrete in the volumeencasing and bonding in composite action the first corner post section,the at least one first reinforcing element and the plurality of secondreinforcing elements. The column may further comprise a second cornerpost section adjacent the first corner post section, wherein each of thesecond reinforcing elements surround the second corner post section,wherein the volume surrounds and includes the second corner postsection, and wherein the concrete in the volume encases and bonds incomposite action the first corner post section, the second corner postsection, the at least one first reinforcing element and the plurality ofsecond reinforcing elements. The at least one first reinforcing elementmay comprise a rebar rod, and the plurality of second reinforcingelements comprise rebar stirrups.

Another aspect of the invention provides a beam in a modular building,the beam comprising: a first horizontal rail of a first volumetricconstruction module; a second horizontal rail of a second volumetricconstruction module, the second horizontal rail parallel to and spacedapart from the first rail; at least one shear connector extending into avolume between the first rail and the second rail and attached to atleast one of the first rail and the second rail; a beam soffit memberbelow the first rail and the second rail, the beam soffit member havingone or more shear connectors extending into the volume between the firstrail and the second rail; and concrete in the volume between the firstrail and the second rail, the concrete bonded in composite action withthe at least one shear connector attached to at least one of the firstrail and the second rail and with the one or more shear connectors ofthe beam soffit member. The first module may have an opening definedabove the first rail, wherein the second module has an opening definedabove the second rail, and wherein an upper face of the concrete bordersthe openings in the first and second modules.

Another aspect of the invention provides a beam in a modular building,the beam comprising: a first horizontal rail of a first volumetricconstruction module; a second horizontal rail of a second volumetricconstruction module, the second horizontal rail parallel to and spacedapart from the first rail; at least one shear connector extendingbetween the first rail and the second rail and attached to at least oneof the first rail and the second rail; at least one first reinforcingelement extending in a direction parallel to a long axis of the firstand second horizontal rail; at plurality of second reinforcing elementsoriented in a plane transverse to the long axis of the first and secondhorizontal rail, each of the second reinforcing elements coupling the atleast one shear connector to the at least one first reinforcing element;and a structural member below the first rail, the second rail, the atleast one first reinforcing element, and the plurality of secondreinforcing elements; and concrete in a volume defined between the firstrail and the second rail, the concrete bonded in composite action withthe at least one shear connector, the at least one first reinforcingelement, and the plurality of second reinforcing elements. Thestructural member may be comprise a hot or cold rolled steel section,such as a plate, I beam or truss. The plurality of second reinforcingelements may be substantially U-shaped, wherein end regions of theU-shape engage the at least one shear connector, and a middle region ofthe U-shape engages the at least one first reinforcing element. The atleast one first reinforcing element may comprise a rebar rod, and theplurality of second reinforcing elements comprise rebar stirrups.

Another aspect of the invention provides a shear wall in a modularbuilding, the shear wall comprising: a shear wall panel; at least aportion of one end or side of a volumetric construction module; at leastone connector rigidly fixed to and extending between the shear wallpanel and the portion of the one end or side; concrete in a volumedefined between the shear wall panel and the portion of one end or side.The shear wall panel may comprise repurposed intermodal shippingcontainer wall material.

Another aspect of the invention provides a volumetric constructionmodule comprising: a frame having opposed ends and opposed sidesextending between the ends; and one or more shear connectors projectingoutwardly from the frame. The frame may comprise at least part of arectangular parallelepiped frame of an intermodal shipping container.The one or more shear connectors may extend between adjacent corners ofthe frame. The one or more shear connectors may comprise an array ofstud-type shear connectors. The one or more shear connectors maycomprise at least one strip-type shear connector. The one or more shearconnectors may be located adjacent an edge of the frame. The edge maycomprise an edge between one of the ends of the frame and one of thesides of the frame. The frame may comprise a plurality of verticalposts, and wherein at least one of the one or more shear connectors isattached to one of the posts. The module may comprise a panel sectioncoupled to the frame, wherein at least one of the one or more shearconnectors is attached to the panel section. The edge may comprise anedge between a bottom of the frame and one of the sides of the frame.The edge may be located along the top of one of the ends. The frame maycomprise a horizontal rail, and at least one of the one or more shearconnectors may be attached to the rail. The frame may have an opening inone of its sides, wherein at least one of the shear connectors extendsalong an edge of the opening.

Another aspect of the invention provides a method for making avolumetric construction module, the method comprising: providing anintermodal shipping container; installing one or more shear connectorson the outside of the container. The method may comprise removing aportion of a side panel of the container to define an opening in a sideof the container. The method may comprise detachably fastening theremoved portion of the side panel to the container. Installing the oneor more shear connectors may comprise: attaching the one or more shearconnectors to the removed portion of the side panel; and laminating theremoved portion of the side panel to a remaining portion of the sidepanel of the container. Installing the one or more shear connectors maycomprise installing one or more shear connectors between adjacentcorners of the container. Installing the one or more shear connectorsmay comprise installing an array of stud-type shear connectors.Installing the one or more shear connectors may comprise installing atleast one strip-type shear connector. Installing the one or more shearconnectors may comprise installing the one or more shear connectorsadjacent to an edge of the container. The edge may comprise an edgebetween an end of the container and a side of the container. Installingthe one or more shear connectors may comprise attaching at least one ofthe one or more shear connectors to a post of the container. Installingthe one or more shear connectors may comprise attaching at least one ofthe one or more shear connectors to a panel of the container. The edgemay comprise an edge between a bottom of the container and a side of thecontainer. The edge may comprise an edge between a top of the containerand an end of the container. Installing the one or more shear connectorsmay comprise attaching at least one of the one or more shear connectorsto a horizontal rail of the container. Installing the one or more shearconnectors may comprise welding at least one of the one or more shearconnectors to the container. Installing the one or more shear connectorsmay comprise adhesively bonding at least one of the one or more shearconnectors to the container. Installing the one or more shear connectorsmay comprise mechanically coupling at least one of the one or more shearconnectors to the container.

Another aspect of the invention provides a building comprising: twovolumetric construction modules in adjacent relation, each modulecomprising: a frame having opposed ends and opposed sides extendingbetween the ends, and one or more first shear connectors coupled to theframe and extending toward the other module; at least one first closuremember closing lateral sides of a first volume between the modules thatincludes the one or more first shear connectors; and concrete occupyingthe first volume. Each module may have an opening defined in its sidethat faces the other module, and wherein the first volume is adjacentthe openings. Each of the modules may comprise one or more second shearconnectors, and wherein the building comprises: at least one secondfirst closure member closing lateral sides of a second volume betweenthe modules that includes the one or more second shear connectors; andconcrete occupying the second volume, wherein the second volume isspaced apart from the first volume and adjacent the openings in themodules. The frame of each module may comprise at least part of arectangular parallelpiped frame of an intermodal shipping container.

Another aspect of the invention provides a building comprising: a firstvolumetric construction module comprising a frame, the frame comprisinga first segment; a volume of a composite segment, the volume integratingthe first segment; and concrete occupying the volume. The building maycomprise a structure adjacent the first volumetric construction module,the adjacent structure comprising a second segment, wherein the volumeintegrates the first segment and the second segment. The adjacentstructure may comprise a second volumetric construction module, anexpansion space, and/or a partially constructed building. The volume maycontain at least a portion of the first and second segments, whereinboundaries of the volume are formed by temporary formwork. The buildingmay comprise a base isolation system.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thedrawings and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings show non-limiting example embodiments.

FIG. 3 is an isometric view of a volumetric construction moduleaccording to an example embodiment.

FIG. 3A is an isometric view of a volumetric construction moduleaccording to an example embodiment.

FIG. 4 is an isometric view of panel sections of the volumetricconstruction module of FIG. 3.

FIG. 4A is a detail isometric view of an angle member installed on apanel section shown in FIG. 4.

FIG. 5 is a side elevation view of the volumetric construction module ofFIG. 3.

FIG. 6 is a top plan view of the top of the volumetric constructionmodule of FIG. 3.

FIG. 7A is an opening end elevation view of the volumetric constructionmodule of FIG. 3.

FIG. 7B is a closed end elevation view of the volumetric constructionmodule of FIG. 3.

FIG. 8A is an isometric view of a column closure member according to anexample embodiment.

FIG. 8B is an isometric view of a column closure member according toanother example embodiment.

FIG. 8C is an isometric view of a column reinforcement member accordingto an example embodiment.

FIG. 9 is an isometric view of a beam soffit member according to anexample embodiment.

FIG. 9A is an isometric view of a panel expansion member according to anexample embodiment.

FIG. 10 is an isometric view of a spacer according to an exampleembodiment.

FIG. 11 is an isometric view of a slab edge form member according to anexample embodiment.

FIG. 12 is an isometric view of an assembly according to an exampleembodiment comprising the volumetric construction module of FIG. 3, themembers of FIGS. 8A, 8B and 9, the spacer of FIG. 10 and the edge formmember of FIG. 11.

FIG. 13 is a flow chart of a construction method according to an exampleembodiment.

FIG. 14 is an isometric view of an assembly illustrating stages ofconstruction according to an example implementation of the method ofFIG. 13.

FIG. 15 is a detail isometric view of a corner of four adjacent modulesassembled according to an example implementation of the method shown inFIG. 13.

FIG. 16 is a cross-section through a composite beam according to anexample embodiment.

FIG. 17 is a cross-section through a composite beam according to anotherexample embodiment.

FIG. 18 is a cross-section through a composite beam according to afurther example embodiment.

FIG. 19 is a cross-section through a composite beam according to afurther example embodiment.

FIG. 20 is a cross-section through a composite beam according to afurther example embodiment.

FIG. 21 is an isometric view of a spacer according to an exampleembodiment.

FIG. 22 is an isometric view of an assembly according to an exampleembodiment comprising the volumetric construction module of FIG. 3, themembers of FIGS. 8B and 9, and the spacer of FIG. 21.

FIG. 23 is a flow chart of a construction method according to an exampleembodiment.

FIG. 24 is an isometric view of an assembly illustrating stages ofconstruction according to an example implementation of the method ofFIG. 23.

FIG. 24A is a close up isometric view of a portion of the assembly ofFIG. 24.

FIG. 25 is an end view cross-section of a portion of the assembly ofFIG. 24.

FIG. 26 is a cross-section through a composite beam according to afurther example embodiment.

FIG. 27 is a cross-section through a composite beam according to afurther example embodiment.

FIG. 27A is a detail isometric view of a corner of four adjacent modulesassembled according to an example implementation of the method shown inFIG. 23.

FIG. 28 is an isometric view of a multi-story building according to anexample embodiment.

FIG. 29 is a floor plan of the building shown in FIG. 28, shown withmodules removed.

FIG. 30 is a floor plan of the building shown in FIG. 28 with modulesshown.

FIG. 31 is a side elevation view of the building core of the buildingshown in FIG. 28.

FIG. 32 is a schematic plan view cross-section through a column formedin part by four corner adjacent opening end corner posts.

FIG. 33 is a schematic plan view cross-section through a column formedin part by four corner adjacent closed end corner posts.

FIG. 34 is a schematic plan view cross-section through a column formedin part by two laterally adjacent closed end corner posts.

FIG. 35 is a schematic plan view cross-section through a column formedin part by two facing adjacent opening end corner posts.

FIG. 36 is a schematic plan view cross-section through a column formedin part by two laterally adjacent opening end corner posts.

FIG. 37 is a schematic plan view cross-section through a column formedin part by one opening end corner post.

FIG. 38 is a schematic plan view cross-section through a column formedin part by four corner adjacent opening end corner posts.

FIG. 39 is a schematic plan view cross-section through a column formedin part by two corner adjacent facing closed end corner posts.

FIG. 40 is a schematic plan view cross-section through a column formedin part by one closed end corner post.

FIG. 41 is a schematic plan view cross-section through a shear wallaccording to an example embodiment.

FIG. 42 is a schematic plan view cross-section through a column formedin part by two facing adjacent opening end corner posts according to anexample embodiment.

FIG. 43 is a schematic plan view cross-section through a column formedin part by an opening end corner posts according to an exampleembodiment.

FIGS. 44 and 44A are isometric and cross section views, respectively,through a composite beam according to an example embodiment.

FIG. 45 is a cross section through a composite beam according to anexample embodiment.

FIG. 46 is a cross section through a composite beam according to anexample embodiment.

FIG. 47 is a cross section through a composite beam according to anexample embodiment.

DESCRIPTION

Throughout the following description specific details are set forth inorder to provide a more thorough understanding to persons skilled in theart. However, well known elements may not have been shown or describedin detail to avoid unnecessarily obscuring the disclosure. Accordingly,the description and drawings are to be regarded in an illustrative,rather than a restrictive, sense.

In some embodiments of the invention, volumetric construction modulesare integrated with concrete and/or other curable materials havinghigh-compressive strength to form composite segments (e.g., columns,beams, slabs, diaphragms, etc. comprising steel and concrete). Inparticular, in some embodiments, one or more segments (e.g. cornerposts, end rails, side rails, etc.) of volumetric construction modulesmay be integrated with a curable material to form the composite segment.Shear connections or other means (e.g. fibre reinforced polymer wraps)may be provided in particular embodiments to augment the structuralcapacity of the composite segment while in other particular embodimentssuch augmentation is not provided (i.e., structural capacity is derivedsolely from the segments integrated with the high strength curablematerial). For simplicity of exposition, a volumetric constructionmodule and various components according to an example embodiment areintroduced first, and this is followed by an explanation of how themodule and components may be combined in a building according to anexample embodiment.

Volumetric construction modules according to some example embodimentscomprise at least some parts of intermodal shipping containers.Presently, intermodal shipping containers can be obtained in developedcountries at relatively low prices (in some cases less than the cost oftheir component materials) due to global trade imbalances. Embodimentswhich comprise intermodal shipping containers may reap cost advantagesfrom the availability of low-cost intermodal shipping containers. Suchembodiments may also reap advantages associated with ease oftransporting these containers, as well as with the standard dimensions,tight tolerances and specified structural capacities to which thesecontainers are built. In some embodiments, the volumetric constructionmodule may comprise other suitable modules including purpose builtmodules. The shape of the volumetric construction module may berectangular or any other shape suitable for the particular application.

FIG. 1 is an isometric view of an intermodal shipping container 10. FIG.2 is a partially-exploded isometric view of container 10. Container 10comprises an International Standards Organization (ISO) high cube 20foot container. Container 10 is 6058 mm (19 feet 10 □ inches) long, 2438mm (8 feet) wide and 2896 mm (9 feet 6 inches) high. Container 10 ismade from weathering steel (e.g., COR-TEN □ weathering steel).

Container 10 comprises a volumetric parallelepiped frame 12. Frame 12comprises a rectangular opening end frame 22 at its opening end 20, arectangular closed end frame 32 at its closed end 30, and rectangularside frames 42L and 42R at its left and right sides 40L and 40R,respectively. Side frames 42L and 42R may be referred to collectively orgenerally herein as side frames 42. The terms □opening end □and □closedend □are used herein to denote the different ends of example containersand shipping modules for convenience only, and it will be understoodthat different container and modules not having opening and closed endsmay be used in embodiments of the invention.

Opening end frame 22 comprises a top opening end rail 24, bottom openingend rail 26, left opening end corner post 28L and right opening endcorner post 28R. Opening end corner posts 28L and 28R may be referred tocollectively or generally herein as corner posts 28. Closed end frame 32comprises a top closed end rail 34, bottom closed end rail 36, leftclosed end corner post 38L (not shown in FIG. 1; see FIG. 2) and rightclosed end corner post 38R. Closed end corner posts 38L and 38R may bereferred to collectively or generally herein as corner posts 38.

Corner fittings 14 are located at each of the corners of opening endframe 20 and closed end frame 30. Corner fittings 14 have orifices 16 ontheir exposed faces for connecting, lifting and lashing container 10during transport and handling. Side rails extend between opposite cornerfittings 14 of opening end frame 22 and closed end frame 32. Moreparticularly:

-   -   top left side rail 44L extends between corner fitting 14 at the        top left corner of opening end frame 22 and corner fitting 14 at        the top left corner of closed end frame 32;    -   top right side rail 44R extends between corner fitting 14 at the        top right corner of opening end frame 22 and corner fitting 14        at the top right corner of closed end frame 32;    -   bottom left side rail 46L (not shown in FIG. 1; see FIG. 2)        extends between corner fitting 14 at the bottom left corner of        opening end frame 22 and corner fitting 14 at the bottom left        corner of closed end frame 32; and    -   bottom right side rail 46R extends between corner fitting 14 at        the bottom right corner of opening end frame 22 and corner        fitting 14 at the bottom right corner of closed end frame 32.

Left side frame 42L comprises left opening corner post 28L, left closedcorner post 38L, top left side rail 44L, and bottom left side rail 46L.Right side frame 42R comprises right opening corner post 28R, rightclosed corner post 38R, top right side rail 44R, and bottom right siderail 46R. As described above, corner posts 28 and 38 are, respectively,also components of opening and closing end frames 22 and 32. Top siderails 44L and 44R may be referred to collectively or generally herein astop side rails 44. Bottom side rails 46L and 46R may be referred tocollectively or generally herein as top side rails 46.

End frames 22 and 32, and side frames 42 are closed by either corrugatedsteel panels or by doors in the case of opening end frame 22. Doors 52hingedly connected to opening end corner posts 28 are pivotable toselectively close opening end frame 22. When closed, doors 52 spanopening end corner posts 28, top opening end rail 24 and bottom openingend rail 26. An end panel 54 closes closed end frame 32. A left sidepanel 56L closes left side frame 42L. A right side panel 56R closesright side frame 42R. The top face of container 10 is closed by a toppanel 58.

The bottom of container 10 comprises a floor frame 62 comprising leftand right bottom side rails 46L and 46R, opening end bottom rail 26 anda closed end bottom rail 36 (not shown in FIG. 1; see FIG. 2). Floorframe 62 is spanned by spaced transverse joists 68. Floor joists 68 arecoupled at their ends to bottom side rails 46. A plywood panel 70 abovefloor frame 62 is fastened to joists 68, bottom side rails 46, openingbottom rail 64, and closed bottom rail 66. Tubular forklift pockets 72intermediate bottom end rails 26 and 36 span bottom side rails 46.

Container 10 is designed and built to be loaded and stacked on containerships. A twenty foot ISO standard intermodal shipping container 10 has atare weight of 2,220 kilograms (4,894 lbs.), can be loaded to a grossweight up to 30,480 kilograms (67,197 lbs.), and can be stacked 9 high(i.e., can support the weight of 8 loaded containers weighing a total of244 metric tonnes). In modern intermodal shipping container designs allcomponents participate in the container structural integrity, and thespecified level of structural capability is assured only when all walls,floors and roofs are in place and doors are closed. Removing any portionof an intermodal shipping container (e.g., to provide windows or doors,or to open up rooms), will compromise structural integrity. Sincewindows, doors, and open rooms are practical necessities for habitablebuildings, construction of multi-story buildings from intermodalshipping containers requires additional support to carry vertical andlateral loads present in these buildings.

Some parts of intermodal shipping containers are stronger than others.For example, floor frame 62 and corner posts 28 and 38 of container 10are relatively strong. More particularly:

-   -   floor frame 62 of container 10 comprises bottom side rails 46,        which are constructed of steel C-channel beams to withstand        longitudinal tensile loads, floor joists 68, which are        constructed of steel C-channel beams to withstand transverse        tensile loads, and bottom end rails 26 and 36, which are        constructed of steel box sections; and    -   corner posts 28 and 38 are constructed from steel C-channel        sections closed with welded steel plate.

Some embodiments of the invention provide volumetric constructionmodules adapted to integrate the relatively strong parts of container 10into composite structural members (e.g., columns, beams, slabs anddiaphragms). Example embodiments of volumetric construction modules andbuildings constructed therefrom using containers such as container 10are described below. It is to be understood that the features andtechniques disclosed herein could also be applied to other types ofcontainers or other types of volumetric construction modules.

FIGS. 3, 4, 4A, 5, 6, 7A and 7B show a volumetric construction module100, or at least portions thereof, according to an example embodiment.More particularly:

-   -   FIG. 3 is an isometric view of module 100;    -   FIG. 4 is an isometric view of panel sections of the module 100;    -   FIG. 4A is a detail isometric view of an angle member installed        on a removable panel section of module 100;    -   FIG. 5 is a side elevation view of module 100;    -   FIG. 6 is a top plan view of module 100;    -   FIG. 7A is an opening end elevation view of module 100; and    -   FIG. 7B is a closed end elevation view of module 100.

Module 100 comprises parts of an intermodal shipping container. Thoseparts are identified using the same reference numerals used to identifylike parts of container 10, and are not described again here. Likecontainer 10, module 100 is laterally symmetric. For convenience,laterally symmetric features of module 100 are described generally withreference to reference numbers indicating these features on the lateralside of module 100 whose outward surface is visible in FIG. 3 (whichside corresponds to left side 40L of container 10). Modules according tosome embodiments of the invention are not laterally symmetric.

Module 100 comprises frame 12. A first opening 22A is defined by openingend frame 22, which in container 10 was selectively closable with doors52. A second opening 32A defined by closed end frame 32, which incontainer 10 was closed by closed panel 54.

Module 100 comprises opposed side openings 102. Openings 102 are definedin part by panel sections 128 and 138 located on the sides 40 of module100 adjacent the opening end 20 and closed end 30, respectively, ofmodule 100. The top and bottom sides of panel sections 128 and 138 areattached, respectively, to top side rail 44 and bottom side rail 46.Panel section 128 is attached along one side to opening end corner post28. Panel section 138 is attached along one side to closed end cornerpost 38.

Openings 102 correspond to removable panel sections 104 shown in FIG. 4.FIG. 4 shows the doors 52, end panel 54 and panel sections 104 removedfrom an intermodal shipping container to create openings 22A, 32A, and102 of module 100. In some embodiments, one or more of doors 52, endpanel 54 and panel sections 104 is detachably fastened to module 100 tocover a corresponding opening in module 100, so as to be optionallydetachable before and/or after module 100 is used in constructing abuilding. Some non-limiting example uses of detachable doors, panels andpanel sections include:

-   -   protecting the interior of module 100 during pre-fabrication of        internal components of module 100 and/or transportation of        module 100,    -   providing selectable building configurations,    -   acting as shoring or formwork during construction of buildings        incorporating module 100,    -   providing structural reinforcement to other panel sections of        module 100 (e.g., by laminating a detachable panel section onto        another panel section coupled to frame 12 by welding, heat        bonding, adhesive, mechanical connection and/or other suitable        laminating techniques),    -   using them as a slab soffit for a composite concrete slab        extending between container modules,    -   and    -   the like.

In FIG. 4, panel sections 128 and 138 are shown positioned according totheir locations on module 100 in order to illustrate how they and panelsections 104 may be obtained from side panels 56 of a container 10.

FIG. 4A is an isometric view of a portion of one of panel sections 104.Panel sections 104 comprise lengths of steel angle 90 along their topedges 104T. A vertical leg of angle 90 is fastened along top edge 104T.A horizontal leg of angle 90 extends perpendicular to panel section 104and is generally aligned with top edge 104T. Angle 90 may be used fordetachably fastening wall section 104 to top side rail 44, such as bytack welds, mechanical fasteners, or the like. Panel sections 104 alsocomprise lengths of steel angle 96 along their bottom edges 104B. Angle96 is similar to angle 90 and may be used for fastening panel sections104 to bottom side rails 46. In similar fashion, closed end panel 54comprises lengths of steel angle (not specifically identified in theFigures) along its top and bottom edges, which may be used to fasten endpanel 54 to close opening 54A of module 100. In some embodiments, module100 comprises connector components (e.g., lengths of steel angle,mechanical fastener components, etc.) to facilitate fastening of panelsections 104 and end panel 54 to module 100.

Module 100 comprises a plurality of shear connectors 110 coupled toframe 12. As described in further detail below, shear connectors 110 mayfacilitate integration of module 100 and components thereof intocomposite structural members. In the illustrated embodiment, arrangementof shear connectors 110 is laterally symmetric, but this is notnecessary.

Sides 40 of module 100 comprises shear connector arrays 112O and 112C.Shear connector arrays 112O and 112C each extend between adjacentcorners of frame 12. Shear connector arrays 112O and 112C are adjacentopening end 20 and closed end 30, respectively, of module 100. In theillustrated embodiment, shear connector arrays 112O and 112C compriseoutwardly projecting shear connectors 110 arrayed on panel sections 128and 138, respectively. More particularly, arrays 112O and 112C eachcomprise a plurality (3) of vertical columns of spaced apart,laterally-extending headed steel shear studs. In array 112O, the shearstuds 110 of the outward vertical column are rigidly connected toopening end corner post 28, through panel section 128, and the shearstuds 110 of the inward vertical columns are rigidly connected to panelsection 128. Similarly, in array 112C, the shear studs 110 of theoutward vertical column are rigidly connected to closed end corner post38, through panel section 138, and the shear studs 110 of the inwardvertical columns are rigidly connected to panel section 138.

Sides 40 of module 100 also comprise shear connector arrays 114. Eachshear connector array 114 comprises outwardly projecting shearconnectors 110 adjacent the bottom of module 100. In the illustratedembodiment, each array 114 comprises a single row of spaced apart,laterally-extending headed steel shear studs. The shear studs 110 ofarrays 114 are rigidly connected to bottom side rails 46.

The angular section at the top face 50 of module 100 comprises a shearconnector array 116. Shear connector array 116 comprises outwardlyprojecting shear connectors 110 adjacent the top of opening end opening22A. More particularly, array 116 comprises a single row of spaced apartheaded steel shear studs welded to the angular portion. The shear studs110 of array 116 are rigidly connected to top opening end rail 24.

Opening end 20 of module 100 comprises a shear connector array 118O.Shear connector array 118O comprises outwardly projecting shearconnectors 110 adjacent the bottom of first opening 22A. In theillustrated embodiment, array 118O comprises a single row of spacedapart headed steel shear studs. The shear studs 110 of array 118O arerigidly connected to opening end bottom rail 26. In some embodiments,module 100 may not have shear connector array 118O (e.g., in embodimentswhere opening end 20 of module 100 forms part of an outward face of abuilding).

Closed end 30 of module 100 comprises a shear connector array 118C.Shear connector array 118C comprises outwardly projecting shearconnectors 110 adjacent the bottom of second opening 32A. In theillustrated embodiment, array 118C comprises a single row of spacedapart headed steel shear studs. The shear studs 110 of array 118C arerigidly connected to closed end bottom rail 36. Shear connector arrays118O and 118C may be referred to interchangeably or collectively hereinas shear connector arrays 118.

Though shear connectors 100 in the illustrated embodiment compriseheaded steel shear studs, in other embodiments any suitable type (orcombination of types) of shear connectors may be provided. Non-limitingexamples of other types of shear connectors that may be used inembodiments include:

shear bolts;

deformed bar anchors;

ties, threaded rods or bolts fastened to opposing members with nuts;

perforated, oscillated, waveform and profiled strips,

T connectors,

Hilti□ HVB connectors;

Hambro□ top cord elements; and

the like.

A row or column of shear connector arrays 112O, 112C, 114 116 and/or 118may comprise as few as one shear connector. For example, in someembodiments, arrays 112O and 112C each comprise three parallel, spacedapart, vertically-oriented strip-type shear connectors. In someembodiments, a few as one shear connector may extend between adjacentcorners of frame 12. For example, array 114, 116 and/or array 118 maycomprise a single strip-type shear connector that extends betweenadjacent corners of frame 12. Though arrays 112O, 112C, 114, 116 and 118of the illustrated embodiment comprise rectangular arrays, this is notnecessary. Arrays of shear connectors need not exhibit regular spacingbetween adjacent shear connectors, and may comprise rows and/or columnshaving different numbers of (and different types of) shear connectors.Arrays of shear connectors may exhibit other geometric patterns, such astriangles, diamonds, arcs, circles and the like, for example.

In some embodiments, at least some shear connectors are arranged onmodule 100 to be staggered with respect to counterpart shear connectorslocated on an opposite side or end of module 100. This may enable shearconnectors of laterally adjacent modules 100 to pass each other inoverlapping fashion when the modules 100 are placed in close laterallyadjacent relation.

As will become more apparent from the discussion below, the type,dimensions arrangement, and spacing of shear connectors may be selectedto provide a desired degree of composite action between module 100 and acurable material integrated with the shear connectors. In someembodiments, shear connectors may be located in different locations thanin the example embodiment illustrated by module 100. For example, one ormore structural members of module 100 that have shear connectorsattached to them may not have shear connectors attached to them in otherembodiments. In some embodiments, shear connectors may be attached tostructural members of a volumetric construction module that do not haveshear connectors in module 100 (e.g., adjacent the top of closed endopening 32A, across top panel 58, on joists 68, etc.).

Shear connectors 110 may be rigidly connected to parts of module 100using any suitable type of connection, such as welding, mechanicalconnection (e.g., captive threaded, nut-retained threaded, riveted,interlocking tab and slot, twist-lock, etc.), adhesive, heat bonding, orthe like, for example. In some embodiments, shear connectors 110 may beconfigured to be installed on module 100 on-site. For example,structural members of module 100 (such as corner posts 28 and 38, andbottom side rails 46, for example) may comprise mechanical fastenercomponents (e.g., holes, threaded apertures, slots, etc.) configured tomate with cooperating fastener components provided on shear connectors110 (e.g., matched studs, threaded studs, notched tabs, etc.). In aparticular example embodiment, shear connectors 110 comprise Nelson□weld studs manufactured by Nelson Stud Welding, and may be installed bya drawn arc stud welding process, such as with a Nelson□ FerruleShooter.

FIG. 3A is an isometric view of module 100 □according to an exampleembodiment. Module 100 □is similar to module 100 except that shearconnector arrays 112O□, 112C □, 114 □, 116 □, and 118C □comprises shearbolts instead of headed studs, shear connector arrays 112O □and 112C□each comprise a single column of shear connectors instead of threecolumns of shear connectors, and each row of shear connector arrays 114□, 116 □, and 118C □comprises fewer numbers of shear connectors. Note inFIG. 3A that the corner post has been cut from the side panel leaving aportion of the heavier gauge cold rolled C shape member on the exteriorof the hot rolled C channel making up the corner post, i.e. the cornerpost has been cut off to improve the aspect ratio of the column andbecause it would otherwise add considerable concrete volume to thecolumn with low steel content. The heavier gauge strip of steel from thecorner post may be left on the corrugated side panel to add rigidity tothe panel in a reuse function, such as the expansion panel memberdescribed further below.

Some embodiments of the invention comprise one or more components thatfacilitate the interconnection of modules 100, the integration ofmodules 100 into composite structural members, and/or the creation of avolumetric space between laterally aligned modules 100. FIGS. 8A, 8B,8C, 9, 9A, 10 and 11 show non-limiting examples of such components.

FIGS. 8A, 8B and 8C are isometric views of column closure members 150and 160 and column reinforcement member 165 according to exampleembodiments. As described in further detail below, members 150, 160 and165 may be used to provide a structural connection between adjacentmodules, and as part of an encasement for a composite structural columnintegrated with modules 100 and to strengthen the column. Thecross-section of steel in the enclosure members may vary to meet thedemand of the specific column. Column closure member 150 comprises asteel C channel 152 having a plurality of shear connectors 154projecting from the base of the channel 152. Column closure member 160comprises a steel C channel 162 having a plurality of shear connectors164 projecting opposite the flange of channel 162. Column reinforcementmember 165 comprises a steel C channel 167 having a plurality of holes169 arranged in the web of channel 167 to receive shear connectors ofthe modules or other components.

Column closure member 160 comprises a steel C channel section 162 havinga plurality of shear connectors 164 projecting opposite the web ofchannel section 162. Shear connectors 164 may be arranged on channelsection 162 so that shear connectors 164 of closure member 160 arestaggered with respect to those of an inverted closure member 160. Thismay enable shear connectors 164 of closure members 160 havingcomplementary orientations (i.e., one inverted, one not inverted) topass each other in overlapping fashion when the closure members 160 areplaced in close opposition.

FIG. 9 is an isometric view of a beam soffit member 170 according to anexample embodiment. As described in further detail below, beam soffitmember 170 may be used to limit the deflection of the bottom side rail46 of column 100, to provide a structural connection between adjacentmodules 100, and to integrate modules the floor frames of modules 100into a structural diaphragm. Member 170 comprises a steel plate 172having a plurality of shear connectors 174 projecting from a major sidethereof.

FIG. 9A is an isometric view of a panel expansion member 175 accordingto an example embodiment. As described in further detail below, panelexpansion members may be used to create an expansion space betweenlaterally aligned modules 100. Panel expansion member 175 comprises apair of beam soffit members 170 coupled to opposite end regions of apanel member 177. Shear connectors 174 of beam soffit members 170 mayproject through corresponding holes in panel member 177 or the shearstuds may be welded through the panel members to the beam soffit memberswith special ferrules as manufactured by Nelson Stud Welding □. Panelmember 177 may for example comprise corrugated side wall steel of anintermodal shipping container.

FIG. 10 is an isometric view of a spacer 180 according to an exampleembodiment. As explained in further detail below, spacer 180 may be usedto align and space vertically and laterally adjacent modules 100 inbuildings according to example embodiments. Spacer 180 comprises a steelbox section 182 closed on five sides, including end side 182E. Spacer180 comprises a first pair of projections 184A and 184B on a top side182T of box section 182 that are opposite a second pair of projections184C and 184D on a bottom side 182B of box section 182. In theillustrated embodiment, projections 184 are configured to be received inthe orifices 16 of corner fittings 14 of ISO standard intermodalshipping containers. A shear connector array 188 extends upwardly frombox section 182 between projections 184A and 184B. Shear connectors 188Aand 188B also extend from opposite ends of box section 182.

In the illustrated embodiments, shear connectors of column closures 150and 160, diaphragm anchoring plate 170 and spacer 180 comprise headedsteel shear studs, but any other suitable type (or combination of types)of shear connector may be used instead of or in addition to headed steelshear studs.

FIG. 11 is an isometric view of a slab edge form member 190 according toan example embodiment. As described in further detail below, slab edgeform member 190 may be used as a form for an edge of a slab of curablematerial (e.g., concrete). Form member 190 comprises a length of anglesteel 192. A vertical leg 192V of angle steel 192 is folded at its topedge 192T toward horizontal leg 192H to form an inclined flap 194.Member 190 comprises a strap 196 attached to flap 194 and extendingdownwardly to a foot 198. An aperture 196A is defined through strap 196and flap 194. Foot 198 is parallel to and spaced apart from horizontalleg 192H. An aperture 198A is defined through foot 198.

FIG. 12 is an isometric view of an assembly 200 according to an exampleembodiment. Assembly 200 partially defines a plurality of volumes intowhich curable material (e.g., concrete) may be introduced to formcomposite structural members (e.g., beams, columns, slabs, etc.).Assembly 200 comprises:

-   -   volumetric construction module 100;    -   a plurality of column closure members 150 and 160 (individually        identified in FIG. 12 as column closure members 150O, 150C, 160O        and 160C);    -   a beam soffit member 170;    -   a plurality of spacers 180 (individually identified in FIG. 12        as spacers 180O and 180C); and    -   a plurality of slab edge form members 190 (individually        identified in FIG. 12 as slab edge form members 190O and 190C).

For convenience, features of the aforementioned components areidentified using the same reference numerals as in their descriptions.

In assembly 200, column closure members 150O and 160O are generallyperpendicular to and abut opposite edges of panel section 128 to closevertically-extending sides of opening end column volume 228. In likefashion column closure members 150C and 160C are generally perpendicularto and abut opposite edges of panel section 138 to closevertically-extending sides of closed end column volume 238. As describedin further detail below, the open vertically-extending sides of columnvolumes 228 and 238 (opposite panel sections 128 and 138, respectively)may be closed by an adjacent volumetric construction module or anothercolumn closure member, so that column volumes 228 and 238 are laterallyenclosed.

Column closure members 160O and 160C also close vertically-extendingfront and rear ends, respectively of a beam volume 246. Onevertically-extending side of beam volume 260 is closed by bottom siderail 46. As described in further detail below, the othervertically-extending side of beam volume 246 (opposite bottom side rail46) may be partially closed by an adjacent volumetric constructionmodule or another beam closure member, so that beam volume 246 islaterally enclosed.

Opening end slab edge form member 190O and opening end spacer 180O forma wall that closes the vertically-extending side of slab volume 260below opening end 20 of module 100. Closed end slab edge form member190C and closed end spacer 180C and form a wall that closes thevertically-extending side of slab volume 260 below closed end 30 ofmodule 100. One projection (not visible in FIG. 11) of each of spacers180O and 180C is engaged with a corresponding orifice 16 of one ofcorner fittings 14. As described in further detail below, the unengagedprojections of spacers 180O and 180C may be mated with the orifices ofthe corner fittings 14 of other modules, such as a module below module100 whose roof closes the bottom of slab volume 260, for example.

Beam soffit member 170 is below and spaced apart from bottom side rail46 and closes a portion of the bottom side of a slab volume 260. Moreparticularly, plate 172 of beam soffit member 170 is level with thebottoms of spacers 180O and 180C. The ends of beam soffit member 170 arealigned with column closure members 150O and 150C. Shear connectors 174of beam soffit member 170 extend through slab volume 260 into beamvolume 246.

It may be observed from FIG. 12 that each of column volumes 228 and 238is closed on at least three vertically-extending sides by steel platehaving shear connectors projecting into the volumes. In particular:

column volume 228 is closed on:

-   -   a first side by C-channel beam 162 of column closure member 160O        and includes shear connectors 164 that project therefrom,    -   a second side by C-channel beam 152 of column closure member        150O and includes shear connectors 154 that project therefrom,        and    -   a third side by panel section 128 and includes shear connectors        110 of array 112O that project therefrom; and

column volume 238 is closed on:

-   -   a first side by C-channel beam 152 of column closure member 150C        and includes shear connectors 152 that project therefrom,    -   a second side by C-channel beam 162 of column closure member        160C and includes shear connectors 164 that project therefrom,        and    -   a third side by panel section 138 and includes shear connectors        110 of array 112C that project therefrom.

When the vertically extending outward sides of column volumes 228 and238 are closed by posts and/or panels of a laterally adjacent moduleand/or other closure members, all vertically-extending sides of each ofcolumn volumes 228 and 238 are closed and the volumes are accordinglylaterally enclosed.

It may also be observed from FIG. 12 that column volumes 228 and 238,beam volume 246 and slab volume 260 are all continuous with each other,and that neighbouring ones of these volumes include shear connectorsrigidly connected to the same structural member. In particular:

-   -   shear connectors 110 of shear connector array 114 on bottom side        rail 46 project into column volumes 228 and 238 and beam volume        246;    -   spacers 180O and 180R have shear connectors 186 that project        into column volumes 228 and 238 and shear connectors 188 that        project into slab volume 260; and    -   shear connectors 174 of beam soffit member 170 extend through        slab volume 260 into beam volume 246.

FIG. 13 is a flow chart of a construction method 300 according to anexample embodiment. FIG. 14 is an isometric view of an assembly 400 offour volumetric construction modules 100 (individually identified inFIG. 14 as 400A, 400B, 400C and 400D) illustrating stages ofconstruction according to an example implementation of method 300.Modules 400A, 400B and 400C are part of a first floor and module 400D islocated on top of module 400A as part of a second floor. FIG. 14 showsconcrete poured after installation of a fifth module 100 on top ofmodule 400B and adjacent to module 400D; the fifth module is not shownin order to expose features of assembly 400 that would otherwise beobscured. Modules 400A, 400B, 400C and 400D are shown without doors 52,closed panels 54 and detachable sections 104 in FIG. 14 to avoidobscuring features of assembly 400. In some embodiments, one or more ofthese components is left in place at one or more of the illustratedstages of construction (e.g., for hoarding and/or shoring until concretehas cured, for permanently dividing adjacent modules, for providingexterior walls, etc.).

Step 302 of method 300 comprises enclosing a slab volume. A slab volumeenclosed in step 302 may be defined in part by the roofs of thevolumetric construction modules (e.g., volumetric construction module100), for example. Or the slab soffit may be enclosed by a repurposedcorrugated panel from the wall of a shipping container. In theillustrated embodiment, step 302 comprises enclosing a slab volumedefined in part by the roofs of volumetric construction modules inspaced laterally adjacent relation, and includes steps 304 and 306.

Step 304 comprises enclosing lateral sides of the slab volume. Enclosinglateral sides of a slab volume may comprise installing spacers 180 andslab edge closures 190 above the top rails of a single module, or abovethe perimeter top rails of a plurality of adjacent modules, for example.FIG. 14 shows an example of this in slab volume 460 which is partiallylaterally enclosed by slab edge closures 190D, which are installed alongthe top opening end rail, top side rail and top closed end rail ofmodule 400D, and spacers 180D, which are installed into the adjacent toporifices of corner fittings of module 400D. Slab volume 460D includesshear connector array 116 located along top opening end rail of module400D.

Step 306 comprises enclosing the space between upper portions of theadjacent sides of laterally adjacent modules. FIG. 14 shows one exampleof step 306 in beam soffit member 470, which is installed atop top siderails 44 of modules 400C and 400B to enclose the space between upperportions of the adjacent sides of modules 400B and 400C.

Step 308 comprises introducing curable material, such as concrete, forexample, to the slab volume enclosed in step 302. FIG. 14 shows anexample of this in composite slab 406, which is visible above module400B but spans the roofs of modules 400A and 400B. Composite slab 406comprises concrete integrated with shear connector arrays 116 of modules400A and 400B (not visible in FIG. 14) and shear connectors 474 of abeam soffit member between modules 400A and 400B (not visible in FIG.14). The concrete of composite slab 406 conforms to the corrugated roofsof modules 400A and 400B (not visible in FIG. 14). In some embodiments,curable material introduced to a slab volume may be further integratedwith the roof(s) the module(s) in order to engage the steel of themodules in composite action, such as with adhesive, embosses, shearconnectors, welded wire mesh and/or the like.

Step 310 of method 300 comprises providing two modules in spacedlaterally adjacent relation, each module having one or more shearconnectors extending toward the other module. This is illustrated inFIG. 14 by the laterally adjacent relation of modules 400A and 400B, andthe laterally adjacent relation of modules 400B and 400C. Step 310 maycomprise placing orifices 16 of adjacent corner fittings 14 of themodules onto projections of spacers 180 of previously placed modules oronto projections installed in a foundation or the like, for example.

Step 312 of method 300 comprises enclosing vertically-extending sides ofone or more volumes between the modules provided in step 310, whichvolume(s) includes one or more shear connectors of the modules. In theillustrated embodiment, step 312 comprises steps 314 and 316.

Step 314 comprises laterally enclosing a beam volume. In someembodiments, step 314 comprises closing vertically extending sides of abeam volume whose other vertically extending sides are defined by bottomside rails 46. For example, step 314 may comprise installing columnclosure members, such as members 160, for example, between adjacentmodules 100. The differences between beam volume 446BC and beam volume446AB exemplify step 314. Beam volume 446BC is closed on two of itsvertically extending sides by adjacent bottom side rails of modules 400Band 400C, but is open on its other vertically-extending sides. Beamvolume 446AB is closed on two of its vertically-extending sides byadjacent bottom side rails of modules 400A and 400B and closed anotherof its other vertically-extending sides by column closure member 160AB.The remaining vertically extending side of beam volume 446AB is closedby a column closure member not visible in the view shown in FIG. 14, sothat beam volume 446AB is laterally enclosed.

It will be appreciated that where step 310 comprises providing twomodules in spaced laterally adjacent relation above a slab (e.g., a slabformed in step 308), the slab may close a bottom side of a beam volumebetween the modules (e.g., in FIG. 14 the top of composite slab 406 islevel with the bottoms of the bottom side rails of module 400D). In thisconnection, it may be observed that step 314 may comprise closingvertically extending sides of a beam volume that includes shearconnectors embedded in a slab below the beam volume. This is exemplifiedin FIG. 14 by shear connectors 474 of beam soffit member 470, whichextend above the top of concrete slab 406, and into the beam volume thatmay be formed above beam soffit member 470.

Step 316 comprises laterally enclosing one or more column volumes. Insome embodiments, step 316 comprises closing vertically extending sidesof a column volume. For example, step 316 may comprise installing columnclosure members, such as members 150 and 160, for example, betweenadjacent modules. The differences between column volume 428BC and columnvolume 428AB exemplify step 316. Column volume 428BC has twovertically-extending sides closed by opposed panel sections 128 ofmodules 400B and 400C, and includes shear connector arrays 112O ofmodules 400B and 400C. The other two vertically-extending sides ofcolumn volume 428BC are open. Column volume 428AB has twovertically-extending sides closed by opposed panel sections 128 ofmodules 400A and 400B, and includes shear connector arrays of modules400A and 400B (not visible in FIG. 14). The other twovertically-extending sides of column volume 428AB are closed by columnclosure members 150AB and 160AB, so that column volume 428AB islaterally enclosed.

In some embodiments, steps 310, 312, 314 and/or 316 may be combined. Forexample, column closure members may be attached to a first module beforethe module is placed in spaced laterally adjacent relation with a secondmodule. For another example, installing column closures 316 maysimultaneously constitute all or part of both steps 314 and 316.

Step 318 comprises introducing curable material, such as concrete, forexample, into a laterally-enclosed volume between the modules placed inlaterally adjacent relation in step 310. In the illustrated embodiment,step 318 comprises steps 320 and 322.

Step 320 comprises introducing curable material to a beam volumeenclosed in step 314. FIG. 14 shows an example of step 320 in compositebeam 404. Composite beam 404 is closed on all but one of its verticallyextending sides by a bottom side rail 46 of module 400D (not visible inFIG. 14) and column closure members 160DO and 160DC, and closed on itsbottom side by composite slab 406. Ordinarily beam 404 would be closedon its remaining vertically-extending side, such as by the bottom siderail of a module above module 400B. The concrete of beam 404 may havebeen formed according to step 320 by introducing concrete to the formdefined by the components closing the vertically-extending sides of beam404. Composite beam 404 comprises concrete integrated with shearconnectors (not visible in FIG. 14) of a diaphragm beam anchoring member(not visible in FIG. 14) that bridges the space between modules 400A and400B.

Step 322 comprises introducing curable material, such as concrete, forexample, to a column volume enclosed in step 316. FIG. 14 shows examplesof step 322, namely:

-   -   column volume 428AB, which is located between the opposed panel        sections 128 of modules 400A and 400B, is laterally enclosed and        filled with concrete (concrete not visible in FIG. 14) to form a        composite column 402AB,    -   column volume 428D, which closed on all but one of its        vertically extending sides by panel 128 of module 400D (this        panel not visible in FIG. 14) and column closure members 150DO        and 160DO, is filled with concrete visible through an open side        of volume 428D to form a composite column 402D, and    -   column volume 438D, which is closed on all but one of its        vertically extending sides by panel 138 of module 400D (this        panel not visible in FIG. 14) and column closure members 150DC        and 160DC, is filled with concrete visible through an open side        of volume 438D to form a composite column 403D.

It will be appreciated that the open sides of column volumes 428D and438D are open for illustrative purposes, and would ordinarily be closedon their remaining vertically-extending sides, such as by panel sections128 and 138, respectively, of a module laterally adjacent to module400D. The concrete of columns 402D and 403D may have been formedaccording to step 322 by introducing concrete to the forms defined bythe components closing the vertically-extending sides of columns 402Dand 403D.

In some embodiments, two or more of steps 308, 318, 320 and 322 arecombined. For example, curable material forming a slab and a beam may beintroduced after the upper modules 100 whose bottom side rails 46 definethe beam volume have been placed above the slab volume. In suchembodiments, the bottom of floor frame 62 of the module 100 above theslab may be left open to permit curable material to enter the spacebetween floor joists 68, or it may be closed (in whole or in part) toprevent curable material from filling (at least some of) the space infloor frame 62. In some embodiments, concrete is introduced intoforklift pockets 72 and/or between pairs of joists 68 (such as throughholes defined in a bottom side rail 46 and/or floor panel 70) to formtransverse beams. In some such embodiments, slabs may not be providedbetween floors of the building (e.g., transverse beams acting incomposite with the module floor may alone provide sufficient strength inthe diaphragm to carry lateral forces to shear walls). In someembodiments, curable material is introduced between modules in step 318to form continuous walls (e.g., detachable panel sections 104 may not beremoved from modules 100).

As the arrangement of modules 400A, 400B and 400C in FIG. 14 shows,method 300 may be practiced with more than two side-by-side adjacentmodules. Method 300 may also be practiced with modules provided inspaced end-to-end adjacent relation, end-to-side adjacent relation, andvarious combinations of spaced side-by-side adjacent, end-to-endadjacent, and/or end-to-side adjacent modules.

Method 300 may be repeated to construct higher floors of a building.Where this is done, step 310 may comprise placing modules 100 of anupper floor above the modules of an immediately lower floor (e.g., inthe manner of module 400D above module 400A). In some embodiments, anupper module may be mounted above a lower module so that the orifices 16of the upper module lower corner fittings 14 receive the projections ofspacers mated with the orifices 16 of corresponding upper cornerfittings 14 of the lower module.

Advantageously, the use of spacers 180 to separate vertically adjacentmodules may permit method 300 to be repeated for a higher floor withoutwaiting for the concrete poured in the lower floor to cure. Inmulti-story reinforced concrete construction, the usual practice is toshore a freshly placed floor on a previously cast floor. The sequenceand rate of erection is governed by the loads placed on the supportingfloor(s) by the weight of the wet concrete and formwork, and by the timerequired to allow the concrete to cure, remove formwork and shoring fromthe cured concrete and then reinstall the formwork and shoring for thenext floor. Method 300 may be performed in a manner that eliminates atleast some of these delays. For example, where spacers 180 placed on thetop corner fittings 14 of the lower modules 100 are at least equal inheight to the depth of a slab to be poured over the roofs of the lowermodules 100, the next, higher floor of modules 100 may be installed andconcrete for that floor poured without shoring before the concrete ofthe lower floor has completely cured, since the spacer 180 will transferthe weight of the upper modules 100 to the lower modules 100 withoutputting pressure on the slab in an early stage of curing.

FIG. 15 is an isometric view of a corner 500 of four adjacent modules100 (individually identified as 500A, 500B, 500C and 500D) assembledaccording to an example implementation of method 300. Corner 500includes components previously introduced, and like numbers are used toindicate like components without further elaboration. In FIG. 15,components are layered to expose the internal elements of compositecolumns 502, composite beam 504 and composite slab 506, and to showdetail of a composite diaphragm 508 formed by the method 300. Diaphragm508 may be viewed as a □sandwich □, having:

-   -   a bottom that includes plate 172 of beam soffit member 170, and        top panels 58 and top opening end rails 24 of modules 500A and        500B;    -   a middle that includes shear connectors 174 of beam soffit        member 170, shear connector arrays 116 of modules 500A and 500B,        and composite slab 506; and    -   a top of that includes beam 504 and floors 60 of modules 500C        and 500D (floors 60 and beam 504 being structurally integrated        by opposed shear connector arrays 114 on adjacent bottom side        rails 46 of modules 500C and 500D).

Diaphragm 508 may also be seen as including a grid of composite beamsthat span the full height of diaphragm 508. The beams □cross-sectionsare defined in part by beam soffit members 170 and bottom side rails 46,and the beams include the full lengths of shear connectors 174 of beamsoffit members 170. Under gravity loads, plates 172 of beam soffitmember 170 acts as tension flanges of the beams, while bottom side rails46 and the concrete encasing shear connectors 174 act as compressionmembers.

The layers of diaphragm 508 are anchored to one another by shearconnectors. In particular, shear connector arrays 116 of modules 500Aand 500B are embedded in composite slab 506 to anchor the bottom ofdiaphragm 508 to the middle of diaphragm 508, and shear connectors 174of beam soffit member 170 anchor the bottom, middle and top of diaphragm508 together. Anchored as such, the top of diaphragm 508, which includesbottom side rails 46, floor joists 68 and plywood panels 70 of modules500C and 500D, provides ductile strength against lateral loads and themiddle and bottom of diaphragm 508 (e.g., concrete slab 506 and toppanels 58) provide rigidity. Advantageously, diaphragm 508 provides thiscombination of ductile strength and rigidity in a shallow floor sectionand with a beam structure in the same plane as the floors 60 of modules100. In some embodiments, diaphragm 508 is structurally connected to abuilding core (e.g., see building 1000 of FIGS. 28-31), and carrieslateral forces to the core to continue the load path through the core tothe foundation.

FIG. 15 also shows how column closure members 150 and 160, panel section128 and corner posts 28 encase the column concrete to form compositecolumn 502. Each of the aforementioned structural components is furtherintegrated with the column concrete by rigidly connected shear connectorarrays (e.g., shear connector array 112O, which is visible in FIG. 15),which bond with the column concrete. In the composite structural memberscolumn 502, beam 504, slab 506 and diaphragm 508, the steel of modules500 and column closure members 150 and 160 provide ductility and tensilestrength for withstanding lateral loads, and the concrete providesstructural rigidity and compressive strength for withstanding gravityloads. The bonding of the steel and concrete with shear connectorscombines the structural advantages of both materials to deliverstructural performance that exceeds the performance of the individualmaterials acting alone.

The encasement of concrete by steel plates in columns 502 and beam 504provides advantages over conventional reinforced concrete. In aconventional reinforced concrete column or beam the concrete is retainedby embedded steel rebar stirrups closely spaced along steel rebar. Whena reinforced concrete column or beam is loaded to failure the concretespalls away from the rebar stirrups, the rebar bends and the column orbeam fails. By contrast, in an encased composite concrete column orbeam, ductile steel, which is well adapted to withstand lateral tensileloads (such as occur during seismic event), is provided on the exteriorof rigid concrete, which is well adapted to withstand verticalcompressive loads. When the column or beam concrete is loaded tofailure, it is confined by the steel confining it and will continue tocarry compressive loads even as it begins to fail. An additionaladvantage is provided by anchoring the encasing steel plate to theconfined concrete with shear connectors. This anchoring arrangementholds the steel encasement flush against the envelope of the concrete,and thereby provides additional resistance to buckling.

The strength of the encasement of columns and beams in method 300 willdepend on the strength of the connection between the members that formthe encasement. In some embodiments, members that form encasements arecontinuously bonded at their adjacent edges, such as by welding,adhesive or the like, to provide additional strength to columns. In someembodiments, members are joined at spaced apart locations (i.e.,non-continuously), such as by tack welds, adhesives and/or mechanicalconnection, for example. In some embodiments, members are notpermanently joined, and clamps or other devices are used to hold themembers together while the curable material they contain has not cured.

In some embodiments, ties or stringers may be installed between opposedencasing members. For example, stringers may be welded between theopposed surfaces of adjacent panels 128 and 138 and/or between opposedcolumn members 150 and 160. For another example, a tie comprising aheaded bolt with a threaded shank may be inserted through matched holeson opposed encasing members, so that the head and the end of the shankare on the outsides of the opposed members, and a nut threaded on theend of the shank to prevent the members from moving laterally apart fromeach other. Ties and/or stringers installed between opposed encasingmembers may function as both shear connectors and encasementreinforcement.

Many variations on the construction of column 502, beam 504, slab 506,diaphragm 508 and the interconnection of column 502 and beam 504 arepossible. The particular construction of the column, beam, slab anddiaphragm and interconnection between column and beam shown in FIG. 15are non-limiting examples. The construction of column 502, beam 504,slab 506, diaphragm 508 and the interconnection of column 502 and beam504 shown in FIG. 15 may be modified to satisfy design criteria. FIGS.16, 17 and 18 show composite beams according to other exampleembodiments.

FIG. 16 is a cross-section through a composite beam 604 according toanother example embodiment. Beam 604 is formed at the interface of fourmodules 600A, 600B, 600C and 600D. Beam 604 differs from beam 504 inthat beam soffit member 670 of beam 604 is supported by a ledger angle614 fastened below the top side rails 44 of lower modules 600A and 600B.As a result, steel plate 672 of beam soffit member 670 is flush with thetop of top side rails 44 of lower modules 600A and 600B, which providesfurther lateral stability.

FIG. 16 demonstrates that a beam soffit member may be lowered further.This may be done, for example, by providing modules 100 with side wallpanels that extend along and below the top side rails. In the context ofa module based on an intermodal shipping container, this may be effectedby removing side panel sections that do not extend up to the top siderails, for example.

FIG. 17 is a cross-section through a beam 704 according to a furtherexample embodiment. In this embodiment, a beam soffit member 770comprises a steel I-beam 772 having shear studs 774 extending from itsupper flange 776. Lower flange 778 of I-beam 772 is supported on ledgerangles 714 fastened to the upper portions of side walls 708 of lowermodules 700A and 700B. I-beam 772 is dimensioned so that its upperflange 776 rests atop top side rails 44 of lower modules 700A and 700B.Shear studs 774 extend upward from top flange 776 through concrete slab706 into the space between bottom side rails 46 of upper modules 700Cand 700D. As compared with beams 504 and 604, beam 704 has greaterstrength and may allow for longer spans and/or heavier floor loads.

FIG. 18 is a cross-section through a beam 804 according to a yet anotherexample embodiment. In this embodiment, a beam soffit member 870comprises a steel I-beam 872. Lower flange 874 of I-beam 872 issupported on ledger angles 814 fastened to the upper portions of sidewalls 808 of lower modules 800A and 800B. The web 876 of I-beam 872extends through concrete slab 810 and into beam 804. The upper flange878 of I-beam 872 is located in the space between opposed bottom siderails 46 of upper modules 800C and 800D. Upper flange 878 of I-beam 872acts as a shear connector to bond concrete in beam 804 to I-beam 872.Web 876 and/or upper flange 878 of I-beam 872 may be perforated,embossed, or provided with tabs, for example, to further integrate it incomposite action with the concrete of beam 804. As compared with beams504, 604 and 704, beam 804 has greater strength and may allow for longerspans and/or heavier floor loads. Alternative encased steel joistdesigns (e.g., castegated beams or trussed joists) may also be employedin the manner of I-beams 772 and 872.

FIG. 19 is a cross-section end view of a composite beam 604 □accordingto another example embodiment. Beam 604 □is a long beam formed betweenmodules 600C □ and 600D □, parallel to the side rails of the modules.Beam 604 □differs from beam 604 in that, like beam 504, beam soffitmember 670 □of beam 604 □is supported by top side rails 44 of lowermodules 600A □and 600B □. Shear studs 674 □of beam soffit member 670 □extend into beam 604 □. Further composite action is provided by shearbolt 680 □extending between the bottom side rails 46 of upper modules600C □and 600D □.

FIG. 20 is a cross-section end view of a composite beam 604

according to another example embodiment. Beam 604

is a short beam formed between modules 600C

and 600D

. Beam soffit member 670

of beam 604

is supported by top end rails 12,24 of lower modules 600A

and 600B

. Shear studs 674

of beam soffit member 670

extend into beam 604

. Further stability is provided by shear bolt 680

extending between the bottom end rails 26,36 of upper modules 600C

and 600D

.

FIG. 21 is an isometric view of a spacer 980 according to anotherexample embodiment. Whereas spacer 180 is configured for aligning andspacing up to four adjacent modules 100, spacer 980 is configured foraligning and spacing two vertically adjacent modules. Spacer 980comprises a steel box 982 which may be closed on all sides or open ontwo sides to allow concrete to enter the void there by providingcomposite connection. Spacer 980 comprises a first projection 984A onone side of box 982 that is opposite a second projection 984B on theopposite side of box 982. In the illustrated embodiment, projections 184are configured to be received in the orifices 16 of corner fittings 14of ISO standard intermodal shipping containers. Shear connector 988A and988B also extend from opposite side of box 982 between projections 984Aand 984B.

FIG. 22 is an isometric view of an assembly 900 according to an exampleembodiment. Assembly 900 partially defines a plurality of volumes intowhich curable material (e.g., concrete) may be introduced to formcomposite structural members (e.g., beams, columns, slabs, etc.).Assembly 900 comprises:

-   -   volumetric construction module 100;    -   a plurality of column closure members 950 and 960 (individually        identified in FIG. 22 as column closure members 950O, 950C, 960O        and 960C), each of which is identical to column closure member        150;    -   a beam soffit member 970, which is a shorter version of beam        soffit member 170; and    -   a plurality of spacers 980

Assembly 900 also comprises components of assembly 200, which are notdescribed again here. For convenience, features of the aforementionedcomponents are identified using the same reference numerals as in theirdescriptions above, and are not described again here.

In assembly 900, column closure members 950O and 950C are generallyperpendicular to and abut inward edges of panel sections 128 and 138,respectively. Column closure members 960O and 960C are generallyparallel to and abut outward edges of panel sections 128 and 138,respectively. Column closure members 950O and 960O closevertically-extending sides of opening end column volume 928. In likefashion column closure members 950C and 960C close vertically-extendingsides of closed end column volume 938. The open vertically-extendingsides of column volumes 928 (opposite panel section 128 and columnclosure member 960O) and 938 (opposite panel section 138 and columnclosure member 960C) may be closed by an adjacent volumetricconstruction module or another column closure member, so that columnvolumes 928 and 938 are laterally enclosed.

Column closure member 960O extends above a beam volume 946. Onevertically-extending side of beam volume 946 is closed by opening endbottom rail 26. Beam volume 946 includes shear connector array 118O,which projects from rail 26. The vertically-extending side of beamvolume 946 opposite rail 26 may be closed, such as by a bottom rail ofanother module (e.g., an end bottom rail of a module in end-adjacentrelation with module 100 of assembly 900, etc.). A beam soffit member970 is below and spaced apart from opening end bottom rail 26. One endof beam soffit member 970 is aligned with column closure members 960O.Shear connectors 974 of beam soffit member 970 extend into beam volume946. It will be appreciated that beam volume 946 is continuous with beamvolume 246 defined by assembly 200 (see FIG. 12), and that a grid ofcontinuous composite beams may be provided by arranging modules 100 in arectangular array and introducing curable material to these beamvolumes.

FIG. 23 is a flowchart of a construction method 300 □according to anexample embodiment. FIG. 24 is an isometric view of an assembly 400 □ofsix volumetric construction modules 100 (individually identified in FIG.24 as 400A □, 400B □, 400C □, 400D □, 400E □and 400F □) illustratingstages of construction according to an example implementation of method300 □. Modules 400A □, 400B □, 400C □and 400D □are part of a firstfloor. Modules 400E □and 400F □are located on top of modules 400A □and400C □, respectively, as part of a second floor. Modules 400A □, 400B □,400C □, 400D □, 400E □and 400F □are shown without doors 52, closedpanels 54 and detachable sections 104 in FIG. 24 to avoid obscuringfeatures of assembly 400 □. In some embodiments, one or more of thesecomponents is left in place at one or more of the illustrated stages ofconstruction (e.g., for hoarding and/or shoring until concrete hascured, for permanently dividing adjacent modules, for providing exteriorwalls, etc.).

The first floor of assembly 400 □also comprises an expansion space 450A□in a side-by-side arrangement between modules 400A □and 400B □, and anexpansion space 450B □in a side-by-side arrangement between modules 400C□and 400D □. Expansion spaces 450A □and 450B □are illustrated with awidth equal to that of the modules. In other embodiments expansionspaces 450A □and 450B □may be narrower or wider than the modules. Anexpansion space provides assembly 400 □with additional interior space ata lower cost than adding a module. Expansion spaces may for example beprovided in sections of assembly 400 □where structural requirements canbe met without the need for adding modules.

FIG. 25 shows a portion of assembly 400 □. Panel expansion member 475□is supported by and spans corresponding top side rails 44 of modules400A □and 400B □to partly define expansion space 450A □. FIG. 26 is aclose up view of panel expansion member 475 □being supported by top siderail 44 of module 400A □. As shown in FIG. 25, a supplemental floorframe 462 □between the floor frames 62 of modules 400A □and 400B □partlydefines expansion space 450A □. FIG. 26 is a close up view ofsupplemental floor frame 462 □of an expansion space 450C □built aboveexpansion space 450A □, wherein supplemental floor frame 462 □is tied tofloor frame 62 of adjacent module 400E □by shear bolts of shearconnector array 114. Supplemental floor frame 462 □of expansion space450A □may be tied in a similar manner to floor frames 62 of modules 400A□and 400B □in FIG. 25. Supplemental floor frame 462 □may be similar inconstruction to floor frame 62.

In other embodiments, expansion spaces may be provided in an end-to-endarrangement between modules, for example as shown in close up in FIG. 27which illustrates a partial view of two stacked modules 410A □and 410C□on the left of the figure and two stacked expansion spaces 415A □and415B □on the right of the figure. Panel expansion member 475 □spans fromtop opening end rail 24 of module 410A □to a top end rail of module 410B□(not shown). Floor frame 462 □of expansion space 415B □is tied to floorframe 62 of module 410C □by bolts of shear array 118O. Plywood flooring495 □covers floor frame 62 and 462 □. Method 300 □may also be practicedwith expansion spaces between modules provided in spaced end-to-endadjacent relation, end-to-side adjacent relation, and variouscombinations of spaced side-by-side adjacent, end-to-end adjacent,and/or end-to-side adjacent modules.

FIG. 25 also shows column reinforcement members 465 □extending from baseregions of corner posts 28,38 to mid-elevation regions of the secondfloor of assembly 400 □(as also shown in FIG. 24). The columns ofassembly 400 □differ from the columns of assembly 400 in that theyinclude column reinforcement members 465 □ which, together with cornerposts 28,38, are encased in a curable material such as concrete to formcomposite columns. Example configurations of column reinforcementmembers 465 □and column posts 28,38 within composite columns are shownin FIGS. 35-37 and 40. Concrete on the exterior of the composite columnsadds a fire rating to assembly 400 □, and further adds strength to thecolumns □axial, shear and bending capacity.

As shown in FIG. 25, formwork 480 □may be positioned to define thecolumn volume and to contain the curable material, such as concrete,until it cures. Shoring 490 □ may also be temporarily positioned alongthe center of the modules to support the top panels 58 of the modules,and along the center of the expansion spaces to support the expansionpanel member 475 □, while curable material for composite slab 406 □ispoured and cured above. Formwork 480 □and shoring 490 □are not shown inFIGS. 24 and 24A for simplicity and clarity.

Construction method 300 □as illustrated in FIG. 23 is similar toconstruction method 300 of FIG. 13 except that construction method 300□contemplates (i) including expansion spaces (e.g. expansion spaces 450A□, 450B □, 450C □, 450D □, 415A □, 415B □) between one or more pairs oflaterally aligned modules and/or (ii) increasing strength of theassembly by forming composite columns with additional column closuremembers embedded within formed columns of curable material (e.g.high-strength concrete, carbon fibre reinforced polymer (CFRP), and thelike). In particular, differences between construction method 300 □andconstruction method 300 may include the following:

-   -   step 304 □□ where the perimeter of an assembly includes one or        more expansion spaces, enclosing the lateral sides of a slab        volume may additionally comprise installing slab edge closures        190 above the perimeter edges of panel expansion members. When        an expansion space is adjacent a module and there are no other        adjacent modules, then a spacer 980 instead of a spacer 180 may        be installed on the top orifice of the corner fitting of the        module to allow vertical stacking of additional modules.    -   step 306 □□ panel expansion members of expansion spaces are        sized so that their side edges abut the top panel edges of        laterally adjacent modules so no additional bridging is        necessary. See for example the arrangement of panel expansion        member 475 □and top panels 58 in FIG. 24A.    -   step 308 □□ the composite slab may alternatively or additionally        span the roofs of modules and expansion spaces. The composite        concrete slab may additionally comprise shear connectors of        panel expansion members. The curable material of the composite        concrete slab conforms to the corrugated top panels of the        modules and the corrugated top surface of panel expansion        members of the expansion spaces. See for example in FIGS. 24A,        26 and 27 the integration of the shear connectors of panel        expansion members 475 □with slab 406 □. In some embodiments,        curable material introduced to a slab volume may be further        integrated with the panel expansion members in order to engage        the steel of the expansion spaces in composite action, such as        with adhesive, embosses, shear connectors, welded wire mesh        and/or the like.    -   step 310 □□ this step may alternatively or additionally comprise        providing an expansion space between two laterally aligned        modules, as shown for example in FIG. 25. Step 310 □therefore        can comprise spanning top side rails of laterally aligned and        spaced apart modules with a panel expansion member, and        installing between the bottom side rails of the modules a        supplemental floor frame, to define an expansion space. Instead        of the side-by-side configuration shown in FIG. 25, an expansion        space may be provided in an end-to-end configuration, as        partially shown in FIG. 27 and described above. Orifices of        corner fittings of modules adjacent an expansion space would be        placed on projections of spacers 180 or 980 of previously placed        modules or onto projections installed in a foundation or the        like, for example.    -   step 312 □□ this step may alternatively or additionally comprise        enclosing vertically-extending sides of one or more volumes        between modules and expansion spaces.    -   step 314 □□ laterally enclosing a beam volume may alternatively        or additionally comprise closing vertically extending sides        defined on one side by a bottom side rail or bottom end rail of        a module and on the other side by a bottom side rail or bottom        end rail of a supplemental floor frame of an expansion space.        The ends of the beam volume may be closed by formworks for a        column instead of a column closure member as in step 314. Where        a slab closes a bottom side of a beam volume between a module        and expansion space (e.g. in FIG. 24A, the top of composite slab        406 □is level with the bottoms of the bottom side rail of second        floor module 400F □and the bottom side rail of supplemental        floor frame of second floor expansion space 450D □), step 314        □would include comprise closing vertically extending sides of a        beam volume that includes shear connectors of panel expansion        member 475 □extending through the top of slab 406 □into the beam        volume. This is shown with long (i.e., side) beam volume 446 □in        FIG. 26 and short (i.e., end) beam volume 447 □in FIG. 27.    -   step 316 □□ laterally enclosing a column volume may        alternatively or additionally comprise temporarily positioning        formworks along one, two, three or all four vertically extending        sides of a column of an assembly. For example, FIG. 25        illustrates formworks 480 □temporarily positioned on two sides        of each of the four columns illustrated. Formworks 480 □for the        other two sides (i.e., the ends) are not shown. Each column also        comprises column reinforcement member 465 □. In some embodiments        column reinforcement members 465 □are bolted with shear bolts to        corner posts of the modules. Example configurations of column        reinforcement members with shear connectors of the module corner        posts within the columns are shown in FIGS. 35-37 and 40.    -   step 318 □—this step comprises introducing curable material,        such as concrete, for example, into a laterally-enclosed slab        volume between the modules and expansion spaces placed in        laterally adjacent relation in step 310 □.    -   step 320 □□ this step comprises introducing curable material,        such as concrete, to a beam volume enclosed in step 314 □. Beam        446 □and 447 □in FIGS. 26 and 27 are examples of cured beam        volumes.    -   step 322 □□ this step comprises introducing curable material,        such as concrete, to a column volume enclosed in step 316 □.        Column 402 in FIGS. 24 and 24A are examples of cured column        volumes.    -   step 324 □□ formworks and shoring are removed once curing        material has cured.

Method 300 □may be repeated to construct higher floors of a building.Where this is done, step 310 □may comprise placing modules 100 of anupper floor above the modules of an immediately lower floor (e.g., inthe manner of module 400 □above module 400A □) and placing expansionspaces of an upper floor above expansion spaces of an immediately lowerfloor (e.g. in the manner of expansion space 450C □above expansion space450A □). In some embodiments, an upper module may be mounted above alower module so that the orifices 16 of the upper module □s lower cornerfittings 14 receive the projections of spacers mated with the orifices16 of corresponding upper corner fittings 14 of the lower module.

FIG. 27A is an isometric view of a corner 500 □of four adjacent modulesassembled according to another example implementation of method 300□without any expansion spaces. Curable material is introduced intoformwork to form column 502 □ during step 322 □of an initial cycle ofmethod 300 □for construction of the floor beneath the four adjacentmodules. Subsequently, curable material is introduced to form slab 506□during step 308 □of a subsequent cycle of method 300 □for constructionof the floor comprising the four adjacent modules. Next, curablematerial is introduced to form beams 504 □during step 320 □the samesubsequent cycle of method 300 □.

FIG. 28 is an isometric view of a multi-story building 1000 according toan example embodiment. Building 1000 comprises core walls 1002 (whichare shear walls positioned in a square or rectangular arrangement aroundstair and or elevator shafts in the region of the center of thebuilding; see FIG. 41 for an example embodiment of a shear wall). Corewalls 1002 protrude through the roof as is common in mid-rise andhigh-rise buildings. The first floor 1004 of building 1000 is a concretesubstructure (e.g., a commercial structure, a parking garage, afoundation at grade, etc.). Modules 1006 are stacked twelve stories highand surround core walls 1002 on three sides. Columns, beams anddiaphragms formed in part by modules 1006 and they are structurallyconnected to one another and lateral loads are carried to core walls1002 then through the core walls to the foundation. Modules 1006 havewindows 1008 at their opening ends. Columns between outward ends ofadjacent modules 1006 are hidden by a building envelope 1010.

FIG. 29 is a floor plan 1100 of multi-story building 1000, shown withoutmodules 1006 and certain interior elements of building 1000 in order toexpose the location of core walls 1002, columns 1102 and beams 1104.Columns 1102 are arranged in a grid, which provides open spans suitablefor various architectural applications. Beams 1104 show the rectangulargrid of the floor diaphragm 1106 which carries lateral loads to theconcrete core walls 1102. Though floor plan 1100 shows columns 1102between every module, in other embodiments, some columns may beeliminated (e.g., columns may be provided between only every secondmodule or every third module). Where columns are eliminated, more robustbeam designs may be used to support longer spans between columns.

FIG. 30 is a floor plan 1200 of a floor of multi-story building 1000,shown with modules, interior finishing and fenestration hardware. Infloor plan 1200, modules 1006 are arranged to provide hallways 1210,studio apartments 1220, and building core 1240.

Hallways 1210 comprise hall modules 1212 in spaced end-wise adjacentrelation. Hall modules 1212 comprise frames of 20 foot intermodalshipping containers.

Studio apartments 1220 comprise pairs of long side adjacent room modules1222. Room modules 1222 comprise frames of 20 foot intermodal shippingcontainers. Room modules 1222 of each apartment 1220 are connected byopenings 1224. Dividing walls 1226 are provided between pairs of roommodules 1222. Dividing walls 1226 may be formed by introducing curablematerial between opposed closed sides of adjacent modules room modules1222 of adjacent apartments 1220. Envelope walls 1228 are provided atthe exterior sides and ends of room modules 1222.

In each studio apartment 1220, curtain walls 1230 are installed tocreate a bathroom and kitchen space and doors 1232 are fitted inopenings of interior walls 1214 for entry from hallway 1210 to openliving spaces of apartments 1220.

Building core 1240 comprises three core units 1244, 1246 and 1248. Firstcore unit 1244 comprises four upright core modules 1242A in spacedlaterally adjacent relation. Core modules 1242A comprise the frames of20 foot intermodal shipping containers. Second core unit 1246 and thirdcore unit 1248 each comprise a core module 1242B. Each core module 1242Bcomprises the frame of a 40 foot intermodal shipping container. Secondcore unit 1246 and third core unit 1248 confine opposite sides of firstcore unit 1244.

Core walls 1002 are provided between core units 1244, 1246 and 1248, andon the outward sides of core units 1244, 1246 and 1248. Core walls maybe made more robust, such as by increasing their thickness, installingrebar mats, providing shear connectors or bolts between panels of coremodules 1242 (e.g., by covering an entire side panel with shearconnectors), and/or laminating additional panels (e.g., detachable panelsections removed from room modules 1222) onto them, for example.

Core modules 1242B of second core unit 1246 and third core unit 1248 areprovided with top and bottom openings. In second core unit 1246,elevator shafts 1254 are provided through these openings. In third coreunit 1248, stairwells 1256 are provided in these openings.

FIG. 31 is a cross-section through core 1002 of building 1000. As can beseen from FIG. 31, core modules 1242B of second core unit 1246 and thirdcore unit 1248 are provided for every floor, and are integrated withdiaphragms 1260 of their respective floors. Core modules 1242A of firstcore unit 1244 are end-wise vertically stacked, and each first core unit1244 spans 3 and ⅔ floors. Vertical core walls 1002 between the adjacentcore units are visible in FIG. 30.

It will be appreciated that the variety of configurations in which shearconnectors may be provided on modules, closure components, and expansionspace components (e.g. panel expansion members and supplemental floorframes), combined with the variety of configurations in which modules,expansion space components, closure components, and reinforcementmembers may be arranged provides virtually limitless freedom in thedesign of composite structure components. FIGS. 32-34 show three examplecolumns that illustrate how different configurations of modules, shearconnectors and closure components may be used to provide differentcolumn designs. The columns shown in FIGS. 32 to 34 may for example beutilized in assembly 400. FIGS. 35-40 show six example columns thatillustrate how different configurations of modules, shear connectors andreinforcement members may be used to provide different column designs.The columns shown in FIGS. 35-40 may for example be utilized in assembly400 □.

FIG. 32 is a schematic plan view cross-section through a column 1400according to an example embodiment. Column 1400 is formed in part byfour corner adjacent opening end corner posts (individually enumeratedas 1410A, 1410B, 1410C and 1410D, referred to collectively herein ascorner posts 1410) of different modules (not shown). Each of cornerposts 1410 has a plurality of shear connectors 1412 extending outwardlyfrom it. In FIG. 32, it may be observed that opposite ones of shearconnectors 1412 of adjacent ones of corner posts 1410 are verticallystaggered. More particularly, in the close laterally adjacent relationof corner posts 1410 in column 1400, shear connectors 1412 of opposingshear connector arrays pass by each other in overlapping fashion.

Corner posts 1410 partially laterally enclose a volume 1420. Curablematerial is not shown in volume 1420 in order to avoid obscuringfeatures of column 1400. The lateral sides of volume 1420 not enclosedby corner posts 1410 are enclosed by column closure members(individually enumerated as 1430A, 1430B, 1430C and 1430D, referred tocollectively herein as column closure members 1430). Each of columnclosure members 1430 has a plurality of shear connectors 1432 extendingfrom one of its major sides. In FIG. 32, it may be observed that theshear connectors 1432 of column closure members 1430A and 1430D arevertically staggered with respect to the shear connectors 1412 of thecorner posts 1410 to which column closure members 1430A and 1430D areadjacent. More particularly:

-   -   shear connectors 1432 of column closure member 1430A overlap at        right angles the shear connectors 1412 of shear connector arrays        of corner posts 1410A and 1410B, which are bridged by column        closure member 1430A; and    -   shear connectors 1432 of column closure member 1430D overlap at        right angles to the shear connectors 1412 of shear connector        arrays of corner posts 1410C and 1410D, which are bridged by        column closure member 1430D.

In FIG. 32, it may also be observed that shear connectors 1432 ofopposing shear connector arrays of column closure members 1430B and1430C pass by each other in overlapping fashion.

FIG. 33 is a schematic plan view cross-section through a column 1500according to an example embodiment. Column 1500 is formed in part byfour corner adjacent closed end corner posts (individually enumerated as1510A, 1510B, 1510C and 1510D, referred to collectively herein as cornerposts 1510) of different modules (not shown). Each of corner posts 1510has a plurality of shear connectors 1512 extending outwardly from it. InFIG. 33, it may be observed that opposite shear connectors 1512 ofadjacent ones of corner posts 1510 are vertically staggered. Moreparticularly, in the close laterally adjacent relation of corner posts1510 in column 1500, shear connectors 1512 of opposing shear connectorarrays of corner posts 1510 pass by each other in overlapping fashion.

Corner posts 1510 partially laterally enclose a volume 1520. Curablematerial is not shown in volume 1520 in order to avoid obscuringfeatures of column 1500. The lateral sides of volume 1520 not enclosedby corner posts 1510 are enclosed by column closure members(individually enumerated as 1530A, 1530B, 1530C and 1530D, referred tocollectively herein as column closure members 1530). Each of columnclosure members 1530 has a plurality of shear connectors 1532 extendingfrom one of its major sides. In FIG. 26, it may be observed thatopposing shear connectors 1532 of opposite ones of column closuremembers 1530 are vertically staggered. More particularly, shearconnectors 1532 of opposing shear connector arrays pass by each other inoverlapping fashion. In FIG. 26, it may also be observed that the shearconnectors 1532 of column closure members 1530 are vertically staggeredwith respect to the shear connectors 1512 of the corner posts 1510 towhich column closure members 1530 are adjacent. More particularly:

-   -   shear connectors 1532 of column closure member 1530A overlap at        right angles the shear connectors 1512 of shear connector arrays        of corner posts 1510A and 1510B, which are bridged by column        closure member 1530A;    -   shear connectors 1532 of column closure member 1530B overlap at        right angles the shear connectors 1512 of shear connector arrays        of corner posts 1510A and 1510D, which are bridged by column        closure member 1530B;    -   shear connectors 1532 of column closure member 1530C overlap at        right angles the shear connectors 1512 of shear connector arrays        of corner posts 1510B and 1510D, which are bridged by column        closure member 1530B; and    -   shear connectors 1532 of column closure member 1530D overlap at        right angles the shear connectors 1512 of shear connector arrays        of corner posts 1510C and 1510D, which are bridged by column        closure member 1530D.

FIG. 34 is a schematic plan view cross-section through a column 1600according to an example embodiment. Column 1600 is formed in part by twolaterally adjacent closed end corner posts (individually enumerated as1610A and 1610B, referred to collectively herein as corner posts 1610)of different modules (not shown). Each of corner posts 1610 has aplurality of shear connectors 1612 extending from one of its majorsides. In FIG. 34, it may be observed that opposite shear connectors1612 of corner posts 1610 are vertically staggered. More particularly,in the close laterally adjacent relation of corner posts 1610 in column1600, shear connectors 1612 of opposing shear connector arrays of cornerposts 1610 pass by each other in overlapping fashion.

Corner posts 1610 partially laterally enclose a volume 1620. Curablematerial is not shown in volume 1620 in order to avoid obscuringfeatures of column 1600. The lateral sides of volume 1620 not enclosedby corner posts 1610 are enclosed by column closure members(individually enumerated as 1630A, 1630B and 1630C, referred tocollectively herein as column closure members 1630) and laminated panelsection 1640. Each of column closure members 1630 has a plurality ofshear connectors 1632 extending from one of its major sides. Laminatedpanel section 1640 comprises two panel sections 1640A and 1640B whichhave been laminated together. A plurality of shear connectors 1642extend from one side of panel section 1640.

In FIG. 34, it may be observed that the shear connectors 1632 of columnclosure members 1630 are vertically staggered with respect to the shearconnectors 1612 of the corner posts 1610 to which column closure members1630 are adjacent. More particularly:

-   -   shear connectors 1632 of column closure member 1630A overlap at        right angles the shear connectors 1612 of shear connector arrays        of corner posts 1610A and 1610B, which are bridged by column        closure member 1630A; and    -   shear connectors 1632 of column closure member 1630B overlap at        right angles to the shear connectors 1612 of a shear connector        array of corner post 1610A; and    -   shear connectors 1632 of column closure member 1630C overlap at        right angles to the shear connectors 1612 of a shear connector        array of corner post 1610B.

In FIG. 34, it may also be observed that shear connectors 1642 of panelsection 1640 are vertically staggered with respect to opposed shearconnectors 1612 of corner posts 1610 and with respect to opposed shearconnectors 1632 of column closure member 1630A. More particularly:

-   -   shear connectors 1642 of panel section 1640 pass by shear        connectors 1612 of opposed shear connector arrays of corner        posts 1610 in overlapping fashion; and    -   shear connectors 1642 of panel section 1640 pass by shear        connectors 1632 of the opposed shear connector array of column        closure member 1630A in overlapping fashion.

FIG. 35 is a schematic plan view cross-section through a column 1500according to an example embodiment. Column 1500 includes two adjacentopening end corner posts facing each other (individually enumerated as1510A and 1510B) of different modules (not shown). Each of corner posts1510A, 1510B has a plurality of shear connectors 1512 extendingoutwardly from it. Shear connectors 1512 are received in holes ofcorresponding column reinforcement members 1565A, 1565B and bolted.Column 1500 is formed by pouring curing material into a column volume1520 enclosed by formwork (not shown).

FIG. 36 is a schematic plan view cross-section through a column 1600according to an example embodiment. Column 1600 includes two adjacentopening end corner posts in a side-by-side configuration (individuallyenumerated as 1610A and 1610B of different modules (not shown). One ofcorner posts 1610A, 1610B has a plurality of shear connectors 1612extending outwardly from it, while the other of corner posts 1610A,1610B has holes for receiving shear connectors 1612 and creating abolted connection. Alternatively, both corner posts may have a pluralityof holes for receiving a plurality of separate shear connectors andcreating bolted connections. Column 1600 is formed by pouring curingmaterial into a column volume 1620 enclosed by formwork (not shown).

FIG. 37 is a schematic plan view cross-section through a column 1700according to an example embodiment. Column 1700 includes an opening endcorner posts 1710. Corner post 1710 has a plurality of shear connectors1712 extending outwardly from it and received in holes of a columnreinforcement member 1765. Column 1700 is formed by pouring curingmaterial into a column volume 1720 enclosed by formwork (not shown).

FIG. 38 is a schematic plan view cross-section through a column 1800according to an example embodiment. Column 1800 includes two pairs ofcorner adjacent opening end corner posts (individually enumerated as1810A, 1810 B, 1810C and 1810D of different modules (not shown). One ofthe corner posts from each pair of corner posts has a plurality of shearconnectors 1812 extending outwardly from it, while the other one of thecorners posts from each pair has holes for receiving shear connectors1812 and creating a bolted connection. Alternatively, all of cornerposts may have a plurality of holes for receiving a plurality ofseparate shear connectors and creating bolted connections. Column 1800is formed by pouring curing material into a column volume 1820 enclosedby formwork (not shown).

FIG. 39 is a schematic plan view cross-section through a column 1900according to an example embodiment. Column 1900 includes two facingclosed end corner posts (individually enumerated as 1910A and 1910B ofdifferent modules (not shown). One of corner posts 1910A, 1910B has aplurality of shear connectors 1912 extending outwardly from it, whilethe other of corner posts 1910A, 1910B has holes for receiving shearconnectors 1912 and creating a bolted connection. Alternatively, bothcorner posts may have a plurality of holes for receiving a plurality ofseparate shear connectors and creating bolted connections. Column 1900is formed by pouring curing material into a column volume 1920 enclosedby formwork (not shown).

FIG. 40 is a schematic plan view cross-section through a column 2000according to an example embodiment. Column 2000 includes a closed endcorner posts 010. Corner post 2010 has a plurality of shear connectors2012 extending outwardly from it and received in holes of a columnreinforcement member 2065. Column 2000 is formed by pouring curingmaterial into a column volume 2020 enclosed by formwork (not shown).

The structural capacity of any building □s design is highly influencedby its □weight and aspect ratio; further, modern building codes dictatestandards for seismic resistance based on probability and site soilconditions. Most reinforced high rise designs combine core walls withrobust beam to column connections to absorb, transfer and dissipatelateral loads, therefore axial and lateral forces are linked throughthese structures. The modular structural systems described here providesaxial load capacity for gravity loads, however, the systems decouplegravity loads and lateral loads. When applied in a traditionalarchitectural schemes as described in this disclosure, the system willhave sufficient inherent lateral load capacity to resist moderate windand seismic loads, however, in areas where the structure is expected toexperience high earthquake or wind loads, the system can be augmented toincrease the load capacity of the structure by transferring, isolatingand/or dissipating lateral forces. There are several methods to dealwith this as set out below:

1. Add a seismic force resisting system such as moment frame, shearwall, braced frame, dampers, or base isolation to the structure.Excessive lateral loads can be resisted by adding dedicated shear wallsor braced frames to the structure. (The lateral loads will betransferred through the floor diaphragms as lateral forces to the shearwalls or braced frames and ultimately to the foundation. FIG. 41 is aschematic plan view cross-section through a shear wall 2100 according toan example embodiment. Shear wall 2100 includes a shear wall volume 2160defined by a shear wall panel 2104 on one side and on the other side amodule 2110, beam 2046, and an expansion space 2150. Shear wall panel2104 may comprise repurposed container wall material. A plurality ofconnectors 2112, such as ties or stringers, rigidly tie shear wall panel2104 to corresponding panels or posts of module 2110 and expansion space2150. Shear wall volume 2160 may additionally include reinforcingmaterial such as rebar (not shown).2. Augment the beam to column connections to transfer the momentresulting from the lateral loads to the length of the columns and beams,for example:a) using gusset plates to create haunches at the beam to columnconnection and/orb) adding steel reinforcements within the concrete to make the beam tocolumn connection a moment connection.3. Add base isolation devices to isolate the structure from thefoundation. Dedicated base isolation devices can be used to absorb mostof the earthquake energy and limit the lateral forces to be transferredto the modular structural system.

Shear walls are a practical method of combining structural stability,architectural segregation and fire separation between areas of abuilding and can be employed efficiently in architectural applicationssuch as residential apartments, hospitals, prison cells and the like.

Augmenting the beam to column connections is also a practical seismicsolution. It limits the need for walls and provides open planarchitectural opportunities but increases the size and weight of thestructure which will increase foundation costs.

Base isolation provides the most sustainable opportunity as thesebuildings are earthquake resistant because lateral forces are absorbedin the isolators rather than by compromising the structure, which is thecase for all code prequalified seismic force resisting systems. Themodular structural system described here provides a stiff structurewhich is ideal for base isolation. Buildings of the present inventionmay accordingly incorporate suitable base isolation systems.

FIG. 42 is a schematic plan view cross-section through a column 2200according to an example embodiment. Column 2200 includes two adjacentopening end corner posts facing each other (individually enumerated as2200A and 2200B) of different modules (not shown). Corner posts 2200Aand 2200B have a plurality of shear stirrups 2212 (rebar bent into arectangular loop with lapping splice hooks at the end) enclosing thecorner posts on one side of the column and vertical rebar reinforcementmembers 2210A, 2210B, 2210C, 2210D and 2210F on the opposing side of thecolumn. Column 2200 is formed by pouring curing material into a columnvolume 2220 enclosed by formwork (not shown). Similar to columnreinforcement member 465 □(see FIG. 25) the vertical rebar reinforcementmay extend to midlevel of the floor above for splicing to additionalmembers extending to the elevation above. Splicing the vertical membersat mid floor elevation stiffens the column as it terminates at analternative location away from the beam column connection and it addsshear strength to the beam to column connection.

FIG. 43 is a schematic plan view cross-section through a column 2300according to an example embodiment. Column 2300 includes an opening endcorner post 2300A. Corner post 2300A has a plurality of shear stirrups2312 enclosing the corner posts on one side of the column and verticalrebar reinforcement members 2310A, 2310B and 2310C on the opposing sideof the column. Column 2300 is formed by pouring curing material into acolumn volume 2320 enclosed by formwork (not shown). Similar to columnreinforcement member 465 □(see FIG. 25) the vertical rebar reinforcementmay extend to midlevel of the floor above for splicing to additionalmembers extending to the following elevation.

Columns 2200 and 2300 can be implemented in place of column 402 □, shownin FIG. 24, with adjacent expansion space. Further columns 2200 and 2300may be implemented to integrate the volumetric modular system describedhere, to a conventional reinforced concrete building or to a steelstructure with Q deck, etc. It should be further noted that shearstirrups shown with hooks in FIGS. 42 and 43 may be spliced withmechanical connectors, for example Lenton Quick Wedge or LentonInterlock rebar splice. By employing these fittings the shear stirrupsmay be more open or in two or more pieces. This allows the substitutionof shear stirrups in place of the shear bolts demonstrated in FIGS. 35and 36 on columns 1500 and 1600.

The demonstration of headed studs, shear bolts or shear stirrups asshear connectors across columns is not intended to be limiting in thatother methods of providing shear connection across columns may beemployed such as carbon-fiber-reinforced polymer wrap as used in seismicupgrading columns, etc. may be employed to integrate the corner posts ofvolumetric construction modules in columns.

FIG. 44 is an isometric view of a composite beam 4404 according toanother example embodiment. Beam 4404 is a long beam formed betweenmodules 600C and 600D (see FIG. 16) parallel to the side rails of themodules. Beam 4404 differs from beam 604 in that the beam soffit member670 is replaced by a non-structural soffit form 4471 straddling the topside rails 44 of the adjacent modules to contain the curable materialand two lengths of structural rebar 4470 are installed a spaced abovethe soffit form 4471 to provide a concrete cover under the rebar forfire rating. Shear stirrups 4474 are U-shaped with hooks at both ends.The lower horizontal portion of the U shaped shear stirrup 4474 passesbelow the two lengths of structural rebar 4470 and the two verticalportions extend into the upper section of beam 4404. Further confinementof the concrete and composite action in the beam is provided by shearbolt 680 extending between the bottom side rails 46 of upper modules600C and 600D and the vertical portions of shear stirrup 4474 with thehooked ends around shear bolt 680.

FIG. 44A is a cross section end view of composite beam 4404.

FIG. 45 is a cross section end view of composite beam 4504 according toa further example embodiment. Beam 4504 is a long beam formed betweenmodule 600C and a panel expansion member with a supplemental floorframe. Beam 4504 is similar to beam 446 □of FIG. 26 except there is nobeam soffit member below the expansion panel. Instead there are twolengths of structural rebar 4470 spaced above the panel expansion memberto provide a concrete cover under the rebar for fire rating. Shearstirrups 4474 are employed in the same manner as in beam 4404.

FIG. 46 is a cross section end view of composite beam 4604 according toa yet further example embodiment. Beam 4604 is an alternative short beamformed between module 600

and 600B

of FIG. 20. Beam 4604 differs from beam 604

in that beam soffit member 670

is replaced by a non-structural form 4671 straddling the top end railsof the adjacent modules to contain the curable material. Two lengths ofstructural rebar 4670 are spaced above the soffit form 4671 to replacethe structural contribution of beam soffit member 670

and provide a concrete cover over the rebar for fire rating. Shearstirrups 4674 are U shaped with hooks at both ends. The lower horizontalportion of the U-shaped shear stirrup 4674 passes below the two lengthsof structural rebar 4670 and the two vertical portions extend into theupper section of beam 4604. Further confinement of the concrete andcomposite action in the beam is provided by shear bolt 680 extendingbetween the bottom end rails of the upper modules 600C

and 600D

and the vertical portions of shear stirrup 4474 with the hooked endsaround shear bolt 680.

FIG. 47 is a cross section end view of composite beam 4704 according toan example embodiment similar to FIG. 27 in that the beam is closed onone side by the bottom end rail of a module and on the other by a framedfloor above an expansion panel. Beam 4704 differs from FIG. 27 in thatinstead of a beam soffit member, there are two lengths of structuralrebar 4470 installed at a spaced distance above the an expansion panelto allow a concrete cover under the rebar for fire rating. Shearstirrups 4774 are U shaped with hooks at both ends. The lower horizontalportion of the U shaped shear stirrup 4774 passes below the two lengthsof structural rebar 4770 and the two vertical portions extend into theupper section of beam 4704. Further confinement of the concrete andcomposite action in the beam is provided by shear bolts 680 extendingbetween the bottom rails of the upper modules and the vertical portionsof shear stirrup 4474 with the hooked ends around shear bolt 680. Itshould be noted that a similar beam configuration may employed betweenfacing expansion panels and floor frames or with a bottom side rail of amodule on one side only, for example, at the edge of a building.

The capacity of the columns and beams described in FIGS. 42 to 47 may beadapted to the buildings structural demand by varying the cross sectionof concrete, the size and quantity of vertical rebar members and thesize, quantity, location and spacing of the shear stirrups. Further, thecapacity of the beam to column connection may be augmented by employingstandard lapped rebar details with hooked stirrups employing engineeringmethods that are well understood by those familiar with the art.

Where a component or feature is referred to above (e.g., container,frame, rail, post, joist, panel, C-channel, plate, module, shearconnector, etc.), unless otherwise indicated, reference to thatcomponent (including a reference to a “means”) should be interpreted asincluding as equivalents of that component any component which performsthe function of the described component (i.e., that is functionallyequivalent), including components which are not structurally equivalentto the disclosed structure which performs the function in theillustrated exemplary embodiments of the invention.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise,” “comprising,” and thelike are to be construed in an inclusive sense, as opposed to anexclusive or exhaustive sense; that is to say, in the sense of“including, but not limited to.” Where the context permits, words in theabove description using the singular or plural number may also includethe plural or singular number respectively. The word “or,” in referenceto a list of two or more items, covers all of the followinginterpretations of the word: any of the items in the list, all of theitems in the list, and any combination of the items in the list.

The above detailed description of example embodiments is not intended tobe exhaustive or to limit this disclosure and claims to the preciseforms disclosed above. While specific examples of, and examples for,embodiments are described above for illustrative purposes, variousequivalent modifications are possible within the scope of thetechnology, as those skilled in the relevant art will recognize.

These and other changes can be made to the system in light of the abovedescription. While the above description describes certain examples ofthe technology, and describes the best mode contemplated, no matter howdetailed the above appears in text, the technology can be practiced inmany ways. As noted above, particular terminology used when describingcertain features or aspects of the system should not be taken to implythat the terminology is being redefined herein to be restricted to anyspecific characteristics, features, or aspects of the system with whichthat terminology is associated. In general, the terms used in thefollowing claims should not be construed to limit the system to thespecific examples disclosed in the specification, unless the abovedescription section explicitly and restrictively defines such terms.Accordingly, the actual scope of the technology encompasses not only thedisclosed examples, but also all equivalent ways of practicing orimplementing the technology under the claims.

Particular structural characteristics (e.g., cross-sectional shape,material composition, etc.) ascribed to components (e.g., frames, rails,joists, posts, panels, etc.) of example embodiments described herein arenot necessary in all embodiments. Accordingly, components should not beinterpreted as being limited to having particular structuralcharacteristics ascribed to them in example embodiments.

From the foregoing, it will be appreciated that specific examples ofapparatus and methods have been described herein for purposes ofillustration, but that various modifications, alterations, additions andpermutations may be made without departing from the practice of theinvention. The embodiments described herein are only examples. Thoseskilled in the art will appreciate that certain features of embodimentsdescribed herein may be used in combination with features of otherembodiments described herein, and that embodiments described herein maybe practised or implemented without all of the features ascribed to themherein. Such variations on described embodiments that would be apparentto the skilled addressee, including variations comprising mixing andmatching of features from different embodiments, are within the scope ofthis invention.

As will be apparent to those skilled in the art in light of theforegoing disclosure, many alterations and modifications are possible inthe practice of this invention without departing from the spirit orscope thereof. For example:

-   -   As an alternative or addition to shear connectors, some        embodiments may couple segments (i.e., frame components such as        the corner posts, side rails, end rails, etc.) by wrapping them        with Fibre Reinforced Polymer (FRP). FRP may include carbon FRP,        glass FRP, and the like.    -   Columns, beams, and slabs may be made arbitrarily thick or thin.    -   The number of shear connectors shown in the illustrated        embodiments is not meant to be specific. The quantity, type,        size and the like of shear connectors required may be specific        to a particular column or building and the illustrated        representation of type and quantity are exemplary only.    -   Lengths of column closures and beam soffit members may be        varied. For example, a column closure may span two or more        vertically arranged modules.    -   Vertically adjacent column closures (e.g., enclosing different        portions of a column that spans two or more floors of a        building) may be joined together, such as by a butt weld, lap        joint and/or the like, for example.    -   Column closures need not have shear connectors.    -   Column closures may have shear connectors projecting from both        major sides, such as for integrating end-wise adjacent modules,        for example.    -   A single column closure may close two or more sides of a column        volume. For example, a column closure may comprise an I-beam        whose flanges each close an opposite side of a column volume        (e.g., similar to I-beam 772).    -   Spacers may be configured for aligning and spacing eight        adjacent modules (i.e., four corner-adjacent upper modules and        four corner adjacent lower modules).    -   Spacers need not engage orifices of corner fittings. For        example, spacers may be welded to top and/or bottom rails        intermediate corners of frames.    -   Volumetric construction modules may incorporate parts of        intermodal shipping containers of various sizes.        -   For example, volumetric construction modules may incorporate            parts of intermodal shipping containers having lengths of            12192 mm (40 feet), 2991 mm (10 feet), 9125 mm (30 feet),            13716 mm (45 feet), 14630 mm (48 feet), and 17154 mm (53            feet).        -   For another example, volumetric construction modules may            incorporate parts of intermodal shipping containers having            widths greater than 8 feet.        -   For a further example, volumetric construction modules may            incorporate parts of standard height intermodal shipping            containers having, which are 2591 mm (8 feet 6 inches) high.    -   Columns need not be formed at the ends of modules. For example,        where a module incorporates a 17154 mm (53 foot) intermodal        shipping container frame, structurally strong corner posts will        be located approximately 6.5 feet inward from the ends of the        module. Shear connectors may be secured to these corner posts,        and columns that include these shear connectors formed adjacent        to the posts.    -   Volumetric construction modules need not incorporate parts of        intermodal shipping containers. Components of intermodal        shipping containers used in descriptions of example embodiments        may be substituted with any functionally equivalent component,        feature or combination of components and/or features.    -   Volumetric construction modules may comprise corner fittings        that, unlike the corner fittings of intermodal shipping        containers, are fabricated from sheet steel or the module may        have a corner post perforated for ease of interconnection with        handling equipment or other modules.    -   Modules of different dimensions may be integrated in the same        building, on different floors or on the same floor.    -   Buildings may comprise modules which differ in one or more of        height, length, width and orientation.    -   Differences in dimension and/or orientation among modules in a        building may be accommodated by dimensional differences among        columns, beam and slabs of the building.    -   Modules need not have floors and/or top panels.    -   Components assembled with example modules in described example        embodiments (e.g., column closure members, beam soffit members,        edge slab closures, spacers, etc.) may be formed, fabricated or        otherwise integrated with the module (e.g., at the factory, on        site but before modules are placed in spaced adjacent relation,        etc.).    -   Components assembled with example modules in described example        embodiments may be integrated with one another (e.g., one or        more spacers and one or more slab edge closures may be provided        as single unit, column closure for enclosing a single column        volume may be provided as a single unit, etc.).    -   Modules, frames and components may comprise materials other than        steel. Non-limiting examples of other suitable materials        include:        -   metals other than steel;        -   wood;        -   engineered wood composites (e.g., comprising wood fibre and            adhesives, etc.);        -   carbon fibre composites;        -   plastics; and        -   the like.    -   Curable materials other than concrete may be introduced into the        structural volumes (e.g., to form composite columns, beams        and/or slabs). Examples of other suitable curable materials        include fibre reinforced polymers, magnesia cement based        materials (e.g., concrete made with magnesium silicate cement,        such as Carbon Negative Cement made by Novacem Limited of        London, United Kingdom), and the like. In some embodiments,        shear connectors are not used where high-strength curable        materials such as Carbon Fibre Reinforced Polymer (CFRP) or high        strength concrete (e.g. concrete reinforced with steel filings)        are used and temporary formwork used to encase the segments        (i.e., corner posts, side rails, etc.) with these curable        materials.    -   Fire rating material, such as intumescent paint, furring and        gypsum board sprayed insulation or the like, for example, may be        provided to protect the exposed structural steel in volumetric        construction modules from heat due to fire.    -   Volumetric construction modules of the present invention may be        adapted to augment any building structure to provide        pre-manufactured highly finished areas. For example, volumetric        construction modules containing kitchens and bathrooms may be        stacked floor by floor and form a portion of the building        structure in a high rise reinforced concrete building and the        modules can be spaced vertically to match the story elevations        floor to floor.

While a number of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced are interpreted to include all such modifications,permutations, additions and sub-combinations as are within their truespirit and scope.

What is claimed is:
 1. A method of modular building construction comprising: (a) providing a first volumetric construction module comprising a frame, the frame comprising a first segment; (b) defining a volume of a composite segment and integrating the first segment with the volume; and (c) filling the volume with a curable material to cast the composite segment.
 2. A method according to claim 1 further comprising prior to step (b), step (a)(i) comprising providing a structure adjacent the first volumetric construction module, the adjacent structure comprising a second segment, and wherein step (b) comprising integrating the first segment and the second segment with the volume.
 3. A method according to claim 2, wherein in step (b) the volume contains at least a portion of the first and second segments.
 4. A method according to claim 3, wherein step (b) comprises defining a boundary of the volume with temporary formwork.
 5. A method according to claim 2, wherein step (b) comprises defining at least a portion of the boundary of the volume with the first and second segments.
 6. A method according to any one of claims 2 to 5, wherein the adjacent structure comprises a second volumetric construction module comprising a frame including the second segment.
 7. A method according to claim 6, comprising prior to step (b), step (a)(ii) comprising augmenting structural capacity of the composite segment.
 8. A method according to claim 7, wherein step (a)(ii) comprises coupling the first segment and/or the second segment to a plurality of shear connectors extending into the volume.
 9. A method according to claim 8 wherein step (a)(ii) further comprises coupling a column reinforcement member to the plurality of shear connectors.
 10. A method according to claim 7 wherein step (a)(ii) comprises providing a column closure member opposite to the first segment and/or the second segment, the column closure member defining a portion of the boundary of the volume.
 11. A method according to claim 10 wherein the column closure member is coupled to a plurality of shear connectors extending into the volume.
 12. A method according to claim 7 wherein step (a)(ii) comprises providing a plurality of first and second reinforcement elements, the first and second reinforcement elements extending in transverse planes with respect to each other.
 13. A method according to claim 12, wherein the first reinforcement elements comprise rebar rods and the second reinforcement elements comprise rebar stirrups.
 14. A method according to claim 8 wherein step (a)(ii) further comprises providing a plurality of first and second reinforcement elements, wherein the second reinforcement elements engage the shear connectors.
 15. A method according to claim 14, wherein the first reinforcement elements comprise rebar rods and the second reinforcement elements comprise rebar stirrups.
 16. A method according to any one of claims 6 to 15 wherein each of the first and second volumetric construction modules has an opening defined in its side that faces the other module, and wherein the volume comprises a space between the modules adjacent the openings.
 17. A method according to any one of claims 6 to 16 wherein the volume comprises a space between adjacent corners of the frame of the at least one of the first and second volumetric construction modules.
 18. A method according to any one of claims 6 to 16 wherein the volume comprises a space adjacent an edge of the frame of at least one of the first and second volumetric construction modules.
 19. A method according to any one of claims 6 to 18 wherein the first and second volumetric construction modules are provided in laterally adjacent relation.
 20. A method according to claim 19 wherein providing the first and second volumetric construction modules in laterally adjacent relation comprises providing the modules such that a side of one module is adjacent a side of the other module, or such that an end of one module is adjacent a side of the other module, or such that an end of one module is adjacent an end of the other module.
 21. A method according to any one of claims 6 to 20 wherein the frame of each of the first and second volumetric construction module comprises a plurality of vertical posts, wherein the volume comprises a space between opposed posts of the modules.
 22. A method according to any one of claims 6 to 20 wherein the frame of each of the first and second volumetric construction module comprises a horizontal rail, wherein the volume comprises a space between opposed rails of the modules.
 23. A method according to any one of claims 6 to 20 wherein each of the first and second volumetric construction module comprises a panel section fastened to the frame, wherein the volume comprises a space between opposed panel sections of the modules.
 24. A method according to any one of claims 6 to 20 comprising bridging adjacent upper portions of the frames with a structural member to provide a bottom boundary of a slab volume.
 25. A method according to claim 24 wherein the structural member comprises one or more upwardly extending shear connectors.
 26. A method according to claim 25 wherein the shear connectors extend past the top of the frames.
 27. A method according to claim 24 wherein a plurality of rebar rods and rebar stirrups are provided in the slab volume.
 28. A method according to any one of claims 24 to 27 wherein the structural member comprises a hot or cold rolled steel section.
 29. A method according to claims 6 to 28 wherein a boundary of the slab volume is partially defined by a spacer installed above the first volumetric construction module and/or the second volumetric construction module.
 30. A method according to claim 29 wherein at least the top corners of the frame of each of the first and second volumetric construction modules comprise corner fittings having upper orifices, wherein the spacer comprises at least one downward projection, and wherein installing the at least one spacer comprises mating the at least one downward projection with one of the upper orifices.
 31. A method according to any one of claims 24 to 30 comprising introducing a curable material to the slab volume.
 32. A method according to any one of 29 to 31 comprising providing an upper volumetric construction module above each of the first and second volumetric construction modules, each of the upper volumetric construction modules comprising a frame.
 33. A method according to claim 32 wherein at least bottom corners of the frame of each upper module comprise corner fittings having lower orifices, wherein the spacer comprises at least one upward projection, and wherein providing the upper volumetric modules above the volumetric construction modules comprises mating the at least one upward projection with one of the lower orifices.
 34. A method according to any one of claims 6 to 33 wherein each of the frames of the first and second volumetric construction modules comprises a rectangular parallelpiped frame.
 35. A method according to claim 34 wherein the rectangular parallelpiped frame comprises at least a part of a frame of an intermodal shipping container.
 36. A method according to any one of claims 6 to 35 wherein the curable material comprises concrete.
 37. A method of modular building construction comprising: (a) providing first and second volumetric construction modules in lateral relation, each module comprising a frame, the frame comprising a first segment; (b) providing a panel expansion member spanning opposing top rails of the frames and a floor frame between opposing bottom rails of the frame, the space between the panel expansion member and the floor frame defining an expansion space, wherein at least one of the panel expansion member and the floor frame comprise a second segment; (c) defining a volume of a composite segment, the volume integrating the first segment and the second segment; and (d) filling the volume with a curable material to cast the composite segment.
 38. A method according to claim 37, wherein in step (c) the volume contains at least a portion of the first and second segments.
 39. A method according to claim 38, wherein step (c) comprises defining a boundary of the volume with temporary formwork.
 40. A method according to claim 37, wherein in step (c) comprises defining at least a portion of the boundary of the volume with the first and second segments.
 41. A method according to any one of claims 37 to 40, comprising prior to step (d) a step (c)(i) comprising augmenting the structural capacity of the composite segment.
 42. A method according to claim 41, wherein step (c)(i) comprises coupling the first segment and/or the second segment to a plurality of shear connectors extending into the volume.
 43. A method according to claim 41, wherein step (c)(i) comprises providing a plurality of first and second reinforcement elements, the first and second reinforcement elements extending in transverse planes with respect to each other.
 44. A method according to claim 43, wherein the first reinforcement elements comprise rebar rods and the second reinforcement elements comprise rebar stirrups.
 45. A method according to any one of claims 37 to 44 wherein each volumetric construction module has an opening defined in its side that faces the expansion space, and wherein the volumes comprises a space between the modules and the expansion space adjacent the openings.
 46. A method according to any one of claims 37 to 44 wherein the volume comprises a space between adjacent corners of the frame of the at least one of the first and second volumetric construction modules.
 47. A method according to any one of claims 37 to 46 wherein the volume comprises a space adjacent an edge of the frame of at least one of the first and second volumetric construction modules.
 48. A method according to any one of claims 37 to 46 wherein a side of the first volumetric construction module is aligned with the side of the second volumetric construction module, with the expansion space located therebetween.
 49. A method according to any one of claims 37 to 46 wherein a side of the first volumetric construction module is aligned with an end of the second volumetric construction module, with the expansion space located therebetween.
 50. A method according to any one of claims 37 to 46 wherein an end of the first volumetric construction module is aligned with an end of the second volumetric construction module, with the expansion space located therebetween.
 51. A method according to any one of claims 37 to 50 wherein the panel expansion member partially defines a bottom boundary of a slab volume above the modules and the expansion space.
 52. A method according to claim 51 wherein the panel expansion member comprises a structural member at two side regions of the panel expansion member wherein spanning opposing top rails comprises resting at least a portion of the structural member on the top rails or on opposing sides of the modules
 53. A method according to claim 52 wherein the structural member comprises a hot or cold rolled steel section.
 54. A method according to claim 52 or 53 wherein the structural member is provided with upwardly projecting shear connectors.
 55. A method according to any one of claims 37 to 54 wherein each of the frames of the first and second volumetric construction modules comprises a rectangular parallelpiped frame.
 56. A method according to claim 55 wherein the rectangular parallelpiped frame comprises at least a part of a frame of an intermodal shipping container.
 57. A method according to claims 37 to 56 wherein the panel expansion member comprises at least a part of a panel of an intermodal shipping container.
 58. A method according to any one of claims 37 to 57 wherein the floor frame comprises at least a part of a floor frame of an intermodal shipping container.
 59. A method according to any one of claims 37 to 58 wherein the curable material comprises concrete.
 60. A method of modular building construction comprising: (a) providing a first volumetric construction module comprising a frame, the frame comprising a first segment; (b) providing a partially constructed building comprising a frame comprising a second segment; (c) defining a volume of a composite segment, the volume integrating the first segment and the second segment; and (d) filling the volume with a curable material to cast the composite segment.
 61. A method according to claim 60, wherein in step (c) the volume contains at least a portion of the first and second segments.
 62. A method according to claim 61, wherein step (c) comprises defining a boundary of the volume with temporary formwork.
 63. A method according to claim 60, wherein step (c) comprises defining at least a portion of the boundary of the volume with the first and second segments.
 64. A method according to any one of claims 60 to 63, comprising prior to step (d) a step (c)(i) comprising augmenting the structural capacity of the composite segment.
 65. A method according to claim 64, wherein step (c)(i) comprises coupling the first segment and/or the second segment to a plurality of shear connectors extending into the volume.
 66. A method according to claim 64 wherein step (c)(i) further comprises providing a plurality of first and second reinforcement elements, the first and second reinforcement elements extending in transverse planes with respect to each other.
 67. A method according to claim 66, wherein the first reinforcement elements comprise rebar rods and the second reinforcement elements comprise rebar stirrups.
 68. A modular building diaphragm comprising: roof panels of first and second volumetric construction modules in laterally adjacent relation; floor frames of third and fourth volumetric construction modules in laterally adjacent relation, the third and fourth modules above the first and second modules, respectively; a beam soffit member connected between upper portions of the first and second modules and having one or more shear connectors extending upwardly between the third and fourth modules; and a continuous body of concrete in contact with at least a portion of each of the roof panels of the first and second modules, the laterally adjacent portions of the third and fourth modules, and the beam soffit member, the concrete bonded in composite action with the one or more shear connectors of the beam soffit member.
 69. A modular building diaphragm comprising: roof panels of first and second volumetric construction modules in laterally adjacent relation; floor frames of third and fourth volumetric construction modules in laterally adjacent relation, the third and fourth modules above the first and second modules and, respectively, bottom rails of the third and fourth modules rigidly connected by at least one shear connector; a structural member connected between upper portions of the first and second modules; and at least one first reinforcing element extending in a direction parallel to a long axis of the bottom rails; a plurality of second reinforcing elements oriented in a plane transverse to the long axis of the bottom rails, each of the second reinforcing elements coupling the at least one shear connector to the at least one first reinforcing element; and a continuous body of concrete in contact with at least a portion of each of the roof panels of the first and second modules, the laterally adjacent portions of the third and fourth modules, the at least one first reinforcing element, the plurality of second reinforcing elements, and the structural member, the concrete bonded in composite action with the one or more shear connectors of the beam soffit member.
 70. A column in a modular building, the column comprising: a first panel section of a first volumetric construction module; a second panel section of a second volumetric construction module, the second panel section parallel to and spaced apart from the first panel section; at least one shear connector extending into a volume between the first panel section and the second panel section and attached to at least one of the first panel section and the second panel section; at least one column closure member closing lateral sides of the volume between the first panel section and the second panel section; and concrete in the volume bonded in composite action with the at least one shear connector.
 71. The column of claim 70 wherein the first module has an opening defined in part by an inward edge of the first panel section, wherein the second module has an opening defined in part by an inward edge of the second panel section, and wherein the at least one column closure member borders the openings in the first and second modules.
 72. The column of claim 71 comprising at least one shear connector attached to the at least more column closure member, wherein the concrete is bonded in composite action with the at least one shear connector attached to the at least one column closure member.
 73. A column in a modular building, the column comprising: a first corner post section of a first volumetric construction module; a first vertically extending reinforcement member; a first plurality of shear connectors rigidly connecting the first corner post section to the first vertically extending reinforcement member; a volume defined by temporary formwork, the volume surrounding and including the first corner post section, the first vertically extending reinforcement member, and the first plurality of shear connectors; and concrete in the volume encasing and bonding in composite action the first corner post section, the first vertically extending reinforcement member, and the first plurality of shear connectors.
 74. The column of claim 73 further comprising: a second corner post section of a second volumetric construction module adjacent the first corner post section; a second vertically extending reinforcement member; a second plurality of shear connectors rigidly connecting the second corner post section to the second vertically extending reinforcement member; wherein the volume additionally surrounds and includes the second corner post section, the second vertically extending reinforcement member, and the second plurality of shear connectors; and wherein the concrete in the volume additionally encases and bonds in composite action the second corner post section, the second vertically extending reinforcement member, and the second plurality of shear connectors.
 75. A column in a modular building, the column comprising: a first corner post section of a first volumetric construction module; a second corner post section of a second volumetric construction module adjacent the first corner post section; a first plurality of shear connectors rigidly connecting the first corner post section to the second corner post section; a volume defined by temporary formwork, the volume surrounding and including the first corner post section, the second corner post section, and the first plurality of shear connectors; and concrete in the volume encasing and bonding in composite action the first corner post section, the second corner post section, and the first plurality of shear connectors.
 76. The column of claim 75, further comprising a third corner post section of a third volumetric construction module adjacent the first or second corner post section; a fourth corner post section of a forth volumetric construction module adjacent the third corner post section; a second plurality of shear connectors rigidly connecting the third corner post section to the fourth corner post section; wherein the volume additionally surrounds and includes the third corner post section, the fourth corner post section, and the second plurality of shear connectors; and wherein the concrete in the volume additionally encases and bonds in composite action the third corner post section, the fourth corner post section, and the second plurality of shear connectors.
 77. A column in a modular building, the column comprising: a first corner post section of a first volumetric construction module; at least one first reinforcing element extending in a direction parallel to a long axis of the first corner post section; at plurality of second reinforcing elements oriented in a plane transverse to the long axis of the first corner post section, each of the second reinforcing elements surrounding both the first corner post section and the at least one first reinforcing element; a volume defined by temporary formwork, the volume surrounding and including the first corner post section, the at least one first reinforcing element and the plurality of second reinforcing elements; and concrete in the volume encasing and bonding in composite action the first corner post section, the at least one first reinforcing element and the plurality of second reinforcing elements.
 78. A column according to claim 77, comprising a second corner post section adjacent the first corner post section, wherein each of the second reinforcing elements surround the second corner post section, wherein the volume surrounds and includes the second corner post section, and wherein the concrete in the volume encases and bonds in composite action the first corner post section, the second corner post section, the at least one first reinforcing element and the plurality of second reinforcing elements.
 79. A column according to claim 77 or 78, wherein the at least one first reinforcing element comprises a rebar rod, and the plurality of second reinforcing elements comprise rebar stirrups.
 80. A beam in a modular building, the beam comprising: a first horizontal rail of a first volumetric construction module; a second horizontal rail of a second volumetric construction module, the second horizontal rail parallel to and spaced apart from the first rail; at least one shear connector extending into a volume between the first rail and the second rail and attached to at least one of the first rail and the second rail; a beam soffit member below the first rail and the second rail, the beam soffit member having one or more shear connectors extending into the volume between the first rail and the second rail; and concrete in the volume between the first rail and the second rail, the concrete bonded in composite action with the at least one shear connector attached to at least one of the first rail and the second rail and with the one or more shear connectors of the beam soffit member.
 81. The beam of claim 80 wherein the first module has an opening defined above the first rail, wherein the second module has an opening defined above the second rail, and wherein an upper face of the concrete borders the openings in the first and second modules.
 82. A beam in a modular building, the beam comprising: a first horizontal rail of a first volumetric construction module; a second horizontal rail of a second volumetric construction module, the second horizontal rail parallel to and spaced apart from the first rail; at least one shear connector extending between the first rail and the second rail and attached to at least one of the first rail and the second rail; at least one first reinforcing element extending in a direction parallel to a long axis of the first and second horizontal rail; at plurality of second reinforcing elements oriented in a plane transverse to the long axis of the first and second horizontal rail, each of the second reinforcing elements coupling the at least one shear connector to the at least one first reinforcing element; and a structural member below the first rail, the second rail, the at least one first reinforcing element, and the plurality of second reinforcing elements; and concrete in a volume defined between the first rail and the second rail, the concrete bonded in composite action with the at least one shear connector, the at least one first reinforcing element, and the plurality of second reinforcing elements.
 83. A column according to claim 82, wherein the structural member comprises a hot or cold rolled steel section.
 84. A column according to claim 82 or 83, wherein the plurality of second reinforcing elements are substantially U-shaped, wherein end regions of the U-shape engage the at least one shear connector, and a middle region of the U-shape engages the at least one first reinforcing element.
 85. A column according to any one of claims 82 to 84, wherein the at least one first reinforcing element comprises a rebar rod, and the plurality of second reinforcing elements comprise rebar stirrups.
 86. A shear wall in a modular building, the shear wall comprising: a shear wall panel; at least a portion of one end or side of a volumetric construction module; at least one connector rigidly fixed to and extending between the shear wall panel and the portion of the one end or side; concrete in a volume defined between the shear wall panel and the portion of the one end or side.
 87. A shear wall according to claim 86 wherein the shear wall panel comprises repurposed intermodal shipping container wall material.
 88. A volumetric construction module comprising: a frame having opposed ends and opposed sides extending between the ends; and one or more shear connectors projecting outwardly from the frame.
 89. A volumetric construction module according to claim 88 wherein the frame comprises at least part of a rectangular parallelepiped frame of an intermodal shipping container.
 90. A volumetric construction module according to claim 88 or 89 wherein the one or more shear connectors extend between adjacent corners of the frame.
 91. A volumetric construction module according to any one of claims 88 to 90 wherein the one or more shear connectors comprises an array of stud-type shear connectors.
 92. A volumetric construction module according to any one of claims 88 to 91 wherein the one or more shear connectors comprises at least one strip-type shear connector.
 93. A volumetric construction module according to any one of claims 88 to 92 wherein the one or more shear connectors is located adjacent an edge of the frame.
 94. A volumetric construction module according to claim 93 wherein the edge comprises an edge between one of the ends of the frame and one of the sides of the frame.
 95. A volumetric construction module according to claim 93 or 94 wherein the frame comprises a plurality of vertical posts, and wherein at least one of the one or more shear connectors is attached to one of the posts.
 96. A volumetric construction module according to any one of claims 93 to 95 comprising a panel section coupled to the frame, and wherein at least one of the one or more shear connectors is attached to the panel section.
 97. A volumetric construction module according to claim 93 wherein the edge comprises an edge between a bottom of the frame and one of the sides of the frame.
 98. A volumetric construction module according to claim 93 wherein the edge is located along the top of one of the ends.
 99. A volumetric construction module according to claim 97 or 98 wherein the frame comprises a horizontal rail, and wherein at least one of the one or more shear connectors is attached the rail.
 100. A volumetric construction module according to any one of claims 88 to 99 wherein the frame has an opening in one of its sides, and wherein at least one of the shear connectors extends along an edge of the opening.
 101. A method for making a volumetric construction module, the method comprising: providing an intermodal shipping container; installing one or more shear connectors on the outside of the container.
 102. The method of claim 101 comprising removing a portion of a side panel of the container to define an opening in a side of the container.
 103. The method of claim 102 comprising detachably fastening the removed portion of the side panel to the container.
 104. The method of claim 102 or 103 wherein installing the one or more shear connectors comprises: attaching the one or more shear connectors to the removed portion of the side panel; and laminating the removed portion of the side panel to a remaining portion of the side panel of the container.
 105. The method of any one of claims 101 to 104 wherein installing the one or more shear connectors comprises installing one or more shear connectors between adjacent corners of the container.
 106. The method of any one of claims 101 to 105 wherein installing the one or more shear connectors comprises installing an array of stud-type shear connectors.
 107. The method of any one of claims 101 to 106 wherein installing the one or more shear connectors comprises installing at least one strip-type shear connector.
 108. The method of any one of claims 101 to 107 wherein installing the one or more shear connectors comprises installing the one or more shear connectors adjacent to an edge of the container.
 109. The method of claim 108 wherein the edge comprises an edge between an end of the container and a side of the container.
 110. The method of claim 109 wherein installing the one or more shear connectors comprises attaching at least one of the one or more shear connectors to a post of the container.
 111. The method of claim 109 or 110 wherein installing the one or more shear connectors comprises attaching at least one of the one or more shear connectors to a panel of the container.
 112. The method of claim 111 wherein the edge comprises an edge between a bottom of the container and a side of the container.
 113. The method of claim 111 wherein the edge comprises an edge between a top of the container and an end of the container.
 114. The method of claim 112 or 113 wherein installing the one or more shear connectors comprises attaching at least one of the one or more shear connectors to a horizontal rail of the container.
 115. The method of any one of claims 101 to 114 wherein installing the one or more shear connectors comprises welding at least one of the one or more shear connectors to the container.
 116. The method of any one of claims 101 to 115 wherein installing the one or more shear connectors comprises adhesively bonding at least one of the one or more shear connectors to the container.
 117. The method of any one of claims 101 to 116 wherein installing the one or more shear connectors comprises mechanically coupling at least one of the one or more shear connectors to the container.
 118. A building comprising: two volumetric construction modules in adjacent relation, each module comprising: a frame having opposed ends and opposed sides extending between the ends, and one or more first shear connectors coupled to the frame and extending toward the other module; at least one first closure member closing lateral sides of a first volume between the modules that includes the one or more first shear connectors; and concrete occupying the first volume.
 119. The building of claim 118 wherein each module has an opening defined in its side that faces the other module, and wherein the first volume is adjacent the openings.
 120. The building of claim 119 wherein each of the modules comprises one or more second shear connectors, and wherein the building comprises: at least one second first closure member closing lateral sides of a second volume between the modules that includes the one or more second shear connectors; and concrete occupying the second volume, wherein the second volume is spaced apart from the first volume and adjacent the openings in the modules.
 121. The building of claim 118 wherein the frame of each module comprises at least part of a rectangular parallelpiped frame of an intermodal shipping container.
 122. A building comprising: a first volumetric construction module comprising a frame, the frame comprising a first segment; a volume of a composite segment, the volume integrating the first segment; and concrete occupying the volume.
 123. A building according to claim 122, comprising a structure adjacent the first volumetric construction module, the adjacent structure comprising a second segment, wherein the volume integrates the first segment and the second segment.
 124. A building according to claim 122, wherein the adjacent structure comprises a second volumetric construction module.
 125. A building according to claim 122, wherein the adjacent structure comprises an expansion space.
 126. A building according to claim 122, wherein the adjacent structure comprises a partially constructed building.
 127. A building according to any one of claims 123 to 126, wherein the volume contains at least a portion of the first and second segments, wherein boundaries of the volume are formed by temporary formwork.
 128. A building according to any one of claims 123 to 127 further comprising a base isolation system.
 129. A method according to claim 4 wherein the adjacent structure comprises a second volumetric construction module comprising a frame including the second segment.
 130. A method according to claim 129 wherein the adjacent structure comprises a second volumetric construction module comprising a frame including the second segment.
 131. A method according to any one of claims 1-4, 129 and 130 wherein the curable material comprises a high strength curable material.
 132. A method according to claim 131 wherein the curable material comprises carbon fibre reinforced polymer or high strength concrete.
 133. A method according to claim 7, wherein step (a)(ii) comprises coupling the first segment and the second segment by wrapping the segments with fibre reinforced polymer wrap. 